A Material Revolution

How new materials are changing the manufacturing industry

Since the historical periods of the Stone Age, Bronze Age, and Iron Age, the development of materials has helped expand the limits of human endeavour and achievement. In the 21st century, demands from such industries as aerospace and automobiles are pushing the frontiers of material properties to more extreme levels.

It is human nature to always look forward to what we wish were possible. The automobile industry is a prime example of this. When Ford released a wish list of materials for future vehicles, some possible life-saving materials were on it. Professor Pim van der Jagt, Executive Technical Leader at Ford’s Research and Advanced Engineering, listed items such as a new type of steel that is three times stronger than current steel, plastic foam that can stabilise structures during accidents, and nano-filler composites that radically reduce weight while increasing strength. (Source: http://articles.sae.org/12297/)

In the modern age, the aerospace industry is also looking ahead to tougher, lighter, and more heat-resistant materials that would lessen emissions, cut fuel costs, and enable higher speeds. So far, in the aviation industry, composites have been the go-to material. According to Dr. Eleanor Merson, a composite research specialist, "Thirty years ago, five to six percent of an aircraft was made up of composites; now, a commercial plane such as the Dreamliner is made up of about 50% composite material."

Although only one-fifth the weight of steel, carbon fibre composites are stronger. The Dreamliner, for example, has carbon fibre composites in its wings, tail, doors, fuselage, and interiors, which makes it a lighter plane. When it comes to aircraft, every kilogramme counts. Experts estimate that reducing the weight of a commercial aircraft by one kilogramme (2.2 pounds) can lower the cost of operating it by around 2,000 to 3,000 euros per year.

A Lamborghini Packed with Composites

Composite materials are increasingly being used in cars, wind turbine blades, and other products. For example, BMW’s electric i3 is made largely of composites. BMW says the lighter weight helps the vehicle travel as much as 160 kilometres on a single charge. Lamborghini’s fierce-looking Veneno Roadster is packed with weight-reducing composite parts that enable an acceleration of 0 to 100 km/hour in 2.9 seconds. Composites are now cheaper to produce, and more companies are making them, but the production of fine-grade composites still requires high temperatures, extremely clean environments, and a labour-intensive process. And machining these fine-grade composites is even more of a challenge.

"Cutting, and especially drilling, in composites is a major challenge," says Merson, who researches composites for Sandvik Coromant. "An aircraft has tens of thousands of holes in it, and the material is very abrasive; carbon fibres quickly wear out the drills."

It is probable that composites will be further strengthened by fibers that have been developed at the nanoscale level. It is also expected that scientists will be able to create nearly perfect solutions on an atomic level. Specialists at the German chemical company Altana AG say that tiny carbon nanotubes can be made 400 times stronger than steel or aluminium and 20 times stronger than conventional carbon fibres.

Coatings are harder than steel

In physical vapour deposition (PVD) and chemical vapour deposition, we can see the structure in microscopes, virtually down to an atomic level, which helps us analyse new solutions before going live.

With the use of tougher materials, there is not as much of a need to use a huge mass of sturdy components in a single structure. Designers are becoming highly selective in choosing materials for different parts of an automobile or aircraft. Some machine parts don’t need to be that strong. This is the philosophy of Ian Scoley, former head of industrial design at Airbus, where he focused on cabin design. Currently the head of industrial design at C&D Zodiac, Scoley says he draws inspiration from bird bones. "They are strong where they need to be, but they are light and open where they need flexibility."

 Advanced Manufacturing Industries

  • Electric vehicles.
  • Robotics.
  • Air structures.
  • Medical devices.
  • Pharmaceuticals.
  • high-volume goods.
  • Rapid prototyping.
  • And much, much more.

 Benefits of Advanced Manufacturing Technologies

  • Rise in quality levels. The primary benefit of advanced manufacturing technologies is quality enhancement.
  • Enhanced Productivity. Advanced manufacturing technologies boost productivity in several ways.
  • Encourages innovation.
  • Reduced production time.