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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.

Mazda's rotary engine may live on as a range extender (UPDATE)

Update: We received a response from Mazda that confirmed plans for a 2019 electric car available in battery-only and range-extended models, but there was no comment on any other details. The text has been updated to reflect this. It may be time for rotary fans to start getting their hopes up a little for a return of the spinning triangle engine. Automotive News spoke with Mitsuo Hitomi, the man in charge of Mazda powertrains, who said there's a very good chance the next implementation of the rotary engine will be as an electric car range extender. The news source also suggests that such a vehicle could be just around the corner, since Akira Kyomen, Mazda's vehicle development program manager, confirmed to Automotive News that the company will have an EV out in 2019 in both pure electric and range-extended versions. We reached out to Mazda for more information, and a representative confirmed both the pure electric and range-extended models for 2019, but couldn't comment on anything else regarding those vehicles. Looking back, we have reason to believe that this really might happen. As far back as 2013, Mazda was working on a rotary-engine range-extended electric car in the form of the Mazda2 RE Range Extender. It had a total range of 250 miles, half of which came from its battery, the other half from a 330 cc rotary engine generator fueled by a 2.6-gallon gas tank. More recently, Mazda has also teased rotary power with the RX-Vision concept at the 2015 Tokyo Motor Show and another rumored rotary concept at this year's show, which could be the design concept teased recently. But most convincing is the patent we found from Mazda that described a range-extended electric car that would specifically use a rotary engine. The powertrain layout looks just like the one used in that Mazda2 concept. There's also the fact that, as we've previously pointed out, and as Hitomi mentioned to Automotive News, the rotary could be a good range-extender due to its compact size and smoothness. Of course it also isn't known for being the most efficient engine, but if it isn't required to provide all the forward propulsion, it could be made small enough that it's frugal, and the added space and weight savings would be important for making the vehicle more practical, adding more batteries, or simply keeping the car lighter. This news might not excite rotary die-hards who have been waiting for an RX-7 and RX-8 successor, but they shouldn't quite abandon hope yet.

Miata buyers prefer a manual gearbox, says Mazda

Earlier, we wrote about Toyota's underwhelming 2018 manual transmission sales figures. To recap – as Toyota's representatives told CarBuzz – the automatic Corolla outsold its manual equivalent to a ratio of 100 to 1, and just one in three Toyota 86 buyers picked a manual version of the rear-drive coupe. What about the other famous rear-wheel-drive offering from Japan, Mazda's MX-5 Miata? A case can be made that an 86 buyer cross-shops the Miata, and vice-versa, but what kind of split do Mazda's sales figures reflect in comparison? We reached out to Mazda for some sales data, and PR program manager Tim Olson told us 76 percent of Miata soft-top buyers go for the classic stick-shift option, leaving just 24 percent of buyers preferring the automatic. Both transmission options for the Miata are six-speed. The figures are based on year-to-date sales data for the 181-hp 2019 Miata, from July 2018 through April 2019. Interestingly, the more coupe or targa-like, retractable hardtop RF variant takes a step towards the 86 when it comes to transmission choices. While RF buyers still preferred the manual, the split was far closer to half and half: 52% went for the manual, and 48% chose the automatic. Perhaps this reflects the RF's more grand tourer-like image, and it might also be indicative of the RF's higher pricing. If you're going to spend nearly $34,000 for a Miata, another $600 for an autobox doesn't necessarily mean that much – choosing the auto on the base, Sport trim level soft top roadster is a $1,350 bump instead. While the $26,650 base Sport isn't exactly spartan, on a roadster it's fine to have less cushiness. With the higher-specced Club trim level, the auto's price tag shrinks to the aforementioned $600, as it is on the RF Club. There's no base Sport for the RF, as the cheapest RF is the $33,865 Club. But still, the manual shifter's snick-snack feel is one of the Miata's classic traits that has been with it since its inception 30 years ago. Sources say fewer than 5% of the original first generation Miatas were made with an automatic gearbox, but it's obvious trends and tastes are changing – although to be fair, automatics are getting much better as well.