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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.

Toyo Tires will bring another wild catalog of rides to SEMA

Toyo Tires carts all kinds of toys to SEMA every year, the rubber company planning another 30 or so automotive exhibits this year in two locations. One of them, the Baja 911, comes with a pedigree not usually associated with the bewildering wares hawked at the Las Vegas show. TJ Russell was once lead fabricator for Singer Vehicle Design, now he's the head of Russell Built Fabrication in Sun Valley, CA. Sticking with the marque he knows well, Russell started with a 1991 Porsche Carrera 4 cabriolet, fitted the interior with a full roll cage, then built a hardtop around it to design a desert runner channeling the old Rothmans safari 911s. Underneath that bodywork lives a box-plate trailing arm suspension with 12 inches of travel, working 15-inch Fifteen52 FIA-approved Gravel wheels and 30-inch Toyo Open Country A/T II tires. Power comes from a purpose-built 3.8-liter air-cooled flat-six with about 350 horsepower — 100 hp more than stock — in a car that weighs 400 pounds less than the original. Oh, and as documented on Instagram with the tagline "All race outside, all business inside," the interior's full of quilted, cross-stitched leather, and Toyo says Russell's going to do a low-volume run of the Baja 911 starting early next year. ruffian-ford-mustang-sema-01 View 10 Photos Chris Ashton built a 1970 Ford Mustang Fastback called the Ruffian Mustang, inspired by the Trans Am Racing Series. The exterior changes are more subtle than one might think – the chin spoiler, hood scoop, and side mirrors are barely exaggerated versions of those on the original car, the intake vents astride the front lights and the steel bumpers teleported from 1970. Changes outside include de-chromed and flush-mounted glass, vented hood, front fenders that are dropped an inch, rear fender vents, dual side-exit pipes, and gargantuan fender flares over staggered Signature One wheels and Toyo Proxes 888 tires. The interior's fitted with a roll cage and race car workings. In spite of the Boss 427 badging, the engine's a 625-hp Chevrolet LS3 V8. button-built-ferrari-355-sema-01 View 13 Photos The Button Built Ferrari BB355TT picks up from last year's stanced BB328GTS widebody that gave many Internet denizens heart attacks. Laid up on a 1999 355 Berlinetta, the BB version appends a widebody kit designed Mitchell Button, rendered by Khyzyl Saleem and drenched in Azzuro la Plata, a color from Ferrari's Scagliette palette first used on a 1967 275GTB Le Mans racer.

Vehicles awarded IIHS Top Safety Pick awards skyrockets for 2015 [w/video]

By practically every measure, passenger vehicles in the US are continuing to get safer. With the year rapidly coming to an end, the Insurance Institute for Highway Safety is releasing its annual list tallying of the scores for the latest vehicles to see how they compare to last year. Judging by the agency's evaluations, the numbers look quite positive. According to the institute, 71 vehicles earned either the Top Safety Pick or Top Safety Pick+ rating so far in its testing for 2015. Among the latest winners, there have been 33 TSP+ awards and 38 TSP medalists. That's a healthy increase over the 22 TSP+ and 17 TSP grades in 2014. The figures appear even more impressive when you consider that it keeps getting harder to earn the + designation. In the latest round of testing, a vehicle must offer some form of front crash prevention automatic braking to get the mark. Previously, just a warning to drivers was necessary. This list also illustrates the ways that automakers adapt to new testing procedures. In 2013 there were 117 TSP ratings and 13 TSP+ awards. Then, the IIHS mandated that to be a safety pick, a model had to score Good in the institute's four crash tests, plus a Good or Acceptable in the small overlap front test. That brought a plunge in 2014 to just 17 TSP grades. With the numbers climbing again, companies apparently have deciphered how to perform better. Some brands especially stood out on this year's list. The IIHS praised Volvo, Mercedes-Benz and Acura for offering standard front crash prevention systems on some models. Subaru received at least one of the awards for all seven of its models. Toyota also had seven, and the Honda brand did too – though the institute counts the two- and four-door versions of the Civic and Accord separately. Check out the full announcement below and a video about this year's winners. The full list can be viewed, here. Safety gains ground: More vehicles earn top honors from IIHS The number of vehicles earning either of the Institute's two awards has jumped to 71 from 39 this time last year, giving consumers more choices for optimum protection in crashes. The number of winners in the top tier - TOP SAFETY PICK+ - has increased by 11 for 2015, despite a tougher standard for front crash prevention. "This is the third year in a row that we are giving automakers a tougher challenge to meet," says IIHS President Adrian Lund.