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Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

2016 Mazda2 gets EPA-rated 43 mpg highway

To paraphrase the famous quote from astronaut Neil Armstrong, that's one small step for man and one giant leap for the Mazda2. The Environmental Protection Agency (EPA) has weighed in on the new Mazda2 version, and says it gets a fuel-economy rating of 33 miles per gallon city and 43 mpg highway with a six-speed automatic transmission. Stick-shift gas-mileage figures are 31 city and 42 highway, which are still substantially better than the 29/35 rating from the most recent iteration of the model. That's about a 15-percent jump in fuel economy, people. More importantly, the Mazda2 beats out competitors such as the Hyundai Accent, Kia Rio Eco and even the Honda Fit in terms of fuel efficiency, which is pretty good company. The Mazda2 boasts a 1.5-liter four-cylinder engine. But it is the upgrade to six-speed transmissions in both manual and automatic versions that seem to be making the biggest difference in the ratings. Mazda started unveiling details about the next-generation Mazda2 last year, and last fall began production of the model at Mazda's new factory in Salamanca, Mexico. At that time, the Japanese automaker had already sold more than 2.4 million Mazda2 vehicles since the model's introduction in 1996. Related Video:

Mazda Kai concept hints at a more muscular, refined Mazda3

Mazda is packing some serious punch for the Tokyo Motor Show, unveiling a stylish hatchback it's calling the Kai Concept to go along with the earlier reveal of the show-stopping Vision Coupe. The compact five-door concept heralds a new generation of cars for the Japanese automaker, which is best known for making sporty, smallish and well-designed vehicles — such as the Mazda3, from which this concept derives its design direction. This version smooths over most of the Mazda3's sharp body creases in favor of smooth, undulating body panels that dramatically reflect light and reflect Mazda's KODO design language. It also gets more narrow, aggressive-looking headlights and a unique overhead profile, with two panes of glass that continue from the windshield and are intersected by a solid-color center, like a U-shaped moonroof. The Kai is powered by a next-generation Skyactiv-X combustion engine, which uses Mazda's proprietary compression ignition system to give the gas-powered engine the fuel efficiency, torque and initial acceleration response of a diesel powertrain. Which is encouraging, considering the Mazda3 already delivers impressive fuel economy. Inside, the concept hints at more refinement, with streamlined chrome accents popping from the black dash and interior panels. It all rests on Mazda's Skyactiv Vehicle Architecture that reflects human-centered design philosophy in everything from redesigned seats to maintain the spine's natural "S" curvature, to NVH tweaks to encourage a quieter, more comfortable ride. Mazda has said it plans to put this concept into production, but there's no word yet on when exactly that will be.Related Video: