Browse Topic: Production

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First Time Quality as an Indicator for Quantifying the Impact of Software Updates in Automotive Production2026-01-0786To be published on 07/01/2026
Vehicle software updates are released more frequently and in increasingly shorter cycles, which places growing pressure on vehicle quality and final assembly line stability. In production environments, software related issues do not remain limited to the digital domain, since errors introduced by software updates can interrupt flashing and commissioning processes, slow down assembly, and increase rework, thereby directly affecting production throughput. Electronic control units (ECUs) are particularly sensitive to software updates because they are flashed and commissioned during vehicle production under strict timing constraints, and changes to flashing sequences, memory structures, configuration parameters, or function definitions can negatively influence commissioning behavior. This paper shows that the impact of software updates on vehicle production can be quantified in a data-driven manner using First Time Quality (FTQ) as an impact measure. FTQ refers to the percentage of ECUs
El Asad, Aiman, Köhler, Katja, Hahn, Michael, Reuss, Hans-Christian
Holistic sound package design for optimal NVH and carbon footprint of a BEV2026-01-0708To be published on 06/20/2026
Vehicle sound packages are usually designed to provide a given level of vehicle NVH comfort, under weight and cost constraints. Optimal comfort results can be obtained by considering the interaction of all the parts as a full physical system. So far, extensive research has already been performed and published on optimizing vehicle sound packages to achieve effective noise reduction at lowest cost and weight. Nowadays, due to the urgency of the transition to carbon neutrality, sound packages must also address the reduction of the full vehicle life cycle carbon emissions. Sound package components should use materials that have a low emission impact during production and that are suitable for recycling at the end of the vehicle’s life. This entails reconsidering the material solutions chosen for the sound package as a whole, rather than for each individual component. This article describes the design process of a sound package involving NVH, sustainability, and weight/cost requirements
Courtois, Theophane, Cardillo, Marco, Criscione, Mattia, Gerges, Youssef, Massocco, Andrea
Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 3602026-26-0734To be published on 06/01/2026
This study presents a comprehensive methodology for optimizing critical UAV structural nodes—specifically Arm Clamps, Landing Gear, and Motor Mounts—using Generative Design (GD) tailored for Fused Filament Fabrication (FFF) with PLA+. Traditional “plate-and-standoff” UAV constructions often utilize orthogonal geometries that induce stress concentrations and fail to leverage the geometric freedom of additive manufacturing. Furthermore, reliance on expensive CNC machining or injection molding creates supply chain bottlenecks for custom or short-run UAV production. While FFF offers geometric freedom, applying it to structural airframe parts introduces challenges regarding anisotropy, layer adhesion, and material brittleness. This research optimizes these components for standard commercial 3D printers by strictly enforcing manufacturing constraints, including a 40-degree maximum overhang and a 0.4 mm nozzle size, to ensure printability without internal support structures. A significant
Krishna Bansal, Vaibhav
Agentic Digital Thread for Managing the Non-Conformities in Manufacturing of Aerospace Products2026-26-0763To be published on 06/01/2026
Aerospace manufacturing operates within an intricate ecosystem where quality, compliance and traceability are critical to success. Conventional digital thread frameworks provide connectivity but remain largely passive, lacking the intelligence to autonomously manage complex non-conformities across the product lifecycle. This paper introduces an Agentic Digital Thread powered by Agentic AI, designed to transform non-conformity management into an adaptive, self-orchestrating system that actively drives decision-making and corrective actions [1, 4]. The proposed architecture employs a Master Agent to coordinate workflows and maintain end-to-end data continuity, while specialized Agents autonomously manage domain-specific tasks. In the pre-manufacturing phase, these agents proactively validate requirements, material conformity and process planning through integration with PLM, MES, ERP, QMS and supplier systems. In the post-manufacturing phase, the framework extends to concession
Veluri, Sastry, Gopala Krishnan, Kannan
Zero-Shot Classification of Additive Manufacturing Anomalies2026-26-0721To be published on 06/01/2026
Additive Manufacturing (AM) process involves building part layer by layer. Some of the AM processes ( Laser and Electron beam based) generate a melt pool during printing process. This melt pool can be captured periodically during AM process using special optical arrangements. These images capture high intensity melted zone, heat affected zone, splattered molten metal particles and overall shape of the melt pool. These images carry similar characteristics for good AM processes within a range. When there is an anomaly the above said characteristics of the melt pool changes, for example a low intensity melted zone signifies low energy condition which can lead to defects like balling etc. Hence the captured image at this condition appears significantly different from other images. The common defects which can be detected by analyzing melt pool images are porosity, spatter, lack of fusion, cracks, balling and keyhole instability. There are many machine learning methods available to quantify
Kuppusamy, Balasundar
Reliability Program StandardJA1000_202108 (Current)5/26/2026
This SAE standard establishes the requirement for suppliers to plan a reliability program that satisfies the following three requirements: a. The supplier shall ascertain customer requirements b. The supplier shall meet customer requirements c. The supplier shall assure that customer requirements have been met
G-41 Reliability
Reliability Program StandardJA1000_201205 (Historical)5/26/2026
This SAE Standard establishes the requirement for suppliers to plan a reliability program that satisfies the following three requirements: a. The supplier shall ascertain customer requirements; b. The supplier shall meet customer requirements; c. The supplier shall assure that customer requirements have been met. This document applies to the specification, design and development, and assurance of any product. This document does not specify the method to be included in the program. Rather, the content of each program must be tailored to satisfy customer requirements using the most appropriate means.
G-41 Reliability
Inflow-Dependent Sensitivity of Layout Optimization Performance: A Case Study of the Lillgrund Wind Farm2026-99-17385/22/2026
Layout optimization is one of the most effective approaches to reduce the power loss induced by turbine wakes. However, the performance of a wind farm is strongly affected by the inflow direction. This paper conducted a sensitivity analysis on a realistic wind farm, Lillgrund Wind Farm, to investigate the sensitivity of inflow direction on the power production of the initial layout and optimal limits. A wake model considering ambient turbulence intensity is adopted together with the wake superposition method to efficiently resolve the flow field in the wind farm. The results indicate that the power production of the initial layout had a significant discrepancy under different inflow directions, and relies on the consistency of inflow direction and layout array directions. The feature of the two main directional sectors is observed from a realistic wind rose. Therefore, two-sector wind roses are adopted in optimization, and the angles of sectors vary among 51 cases. After optimization
Yang, Kun, Deng, Xiaowei
Cabbage Cleaning Device Based on Fischertechnik Model2026-99-07345/15/2026
This article focuses on the problem of high labor cost, low processing efficiency and poor automation of the existing equipment in the postharvest processing of Chinese cabbage. It will design and produce an automated Chinese cabbage processing method called Smart Fresh Pack. Root removal, leaf removal, washing, loading, weighing, packaging and labeling functions were integrated, and smart dexterous intelligence was applied to core concepts and this can be used in the bulk production scenario of supermarkets in the city and countryside Compared with traditional assembly line equipment, obvious advantages in terms of structure, function and processing capacity: Key innovations include: Low-pressure air jet cleaning replaces water washing, which prevents a second contamination and weighing error due to surface moisture; pneumatic gripper and multi-DOF robotic arms combine to package and dynamically weigh simultaneously, streamlining these tasks; machine vision relies on an SSD
Chen, Yuhui, Zhang, Yixuan, Ruan, Jia, Zhu, Huayun, He, Lianzheng, Zhao, Ping
Evaluation of Mechanical Tensile Properties on TIG-Welded AISI 304L Austenitic Stainless Steel Using Principal Component Analysis05-19-04-00275/14/2026
The reliability of welded joints is a vital factor in modern manufacturing, directly affecting product performance and durability. This study investigates methods to enhance the mechanical and metallurgical quality of butt joints in AISI 304L stainless steel welded by the gas tungsten arc (GTA) process. A systematic experimental design was implemented using the Taguchi method with an L9 orthogonal array, considering welding current, gas flow rate, and travel speed as the main parameters. To determine overall weld performance, the joints were characterized by measuring ultimate tensile strength (UTS), yield strength, percentage elongation, and examining their microstructural morphology. An experimental strategy based on the Taguchi approach has been implemented. The welding performance of the material was investigated, and the process parameters were optimized using multiresponse optimization through principal component analysis (PCA), incorporating an orthogonal array design, signal-to
Ghosh, Nabendu, Roy, Angshuman
SAE TOMORROW TODAY - Why Curing Motion Sickness Is Key to AV Success135675/11/2026
Did you know that motion sickness affects 1 in 3 people? As AVs gain traction and drivers become passengers, it may be the biggest barrier to the future of autonomous mobility. With a focus on addressing the root cause of motion sickness, Motion Sync offers breakthrough solution: a haptic pre-activation system that helps passengers anticipate vehicle movement with a personalized in-cabin experience that could redefine comfort and productivity. Listen in as we sit down with Dr. Daniel Sousa Schulman, CEO and Founder of Motion Sync, to unpack the science behind motion sickness and why it's a critical issue for EVs, robotaxis, and self-driving cars. You'll learn why passengers get sick, why drivers don't, and how EVs can actually make symptoms worse. As a topic critical to the success of autonomous vehicles, it's a conversation you don't want to miss. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take
Patterson, Lori
Synthetic Rubber Hot Oil Resistant, High Swell 45 - 55AMS3222J (Current)4/28/2026
This specification covers a synthetic rubber in the form of sheet, strip, tubing, extrusions, and molded shapes. This specification should not be used for molded rings, compression seals, O-ring cords, and molded in place gaskets for aeronautical and aerospace applications without complete consideration of the end use prior to the selection this material.
AMS CE Elastomers Committee
High-Speed Flashing in the Age of the Software-Defined Vehicle2026-01-01124/7/2026
In recent years, the use of software-defined platforms has become increasingly prevalent. As a result, flashing ECUs has become an important factor in ensuring efficiency, quality, and compliance in vehicle production. Conventional approaches, such as final end-of-line flashing, are increasingly unsuitable for the growing amounts of data, complex dependencies, mixed physics and protocols, and traceability requirements. This SAE paper presents the current trends and challenges in ECU flashing. It highlights the impact of the exponential growth in software payloads and the necessary migration to offline and parallel workflows. This can only be achieved through closer integration with automated and robot-assisted production, considering the requirements of cybersecurity and verifiability. It also addresses the shift toward end-to-end flashing ecosystems, where updates are performed consistently from a single source covering the assembly line, warehouses, yards, workshops, and over-the-air
Böhlen, Boris, Budak, Oguz, Wells, Michael
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-02484/7/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as
Sopher, Steven, Parker, Joshua
Multi-Objective Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing2026-01-02574/7/2026
Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high stiffness-to-weight advantages of composite materials, making it a promising approach for lightweight automotive components. The mechanical performance of fiber-reinforced composites is strongly influenced by fiber orientation, which highlights the importance of optimization methods that can effectively exploit anisotropic behavior. Existing FRAM optimization research has focused primarily on structural performance and has given limited attention to manufacturability challenges. This gap is significant, as overhangs and the resulting need for support structures can substantially increase print time, material consumption, and production cost, restricting broader industrial uptake. This research introduces a multi-objective topology optimization framework that incorporates Design for Additive Manufacturing (DfAM) principles by minimizing both structural compliance and
Wotten, Erik, Kim, Il Yong
From Reactive to Proactive: Applying Data Analysis and Automation to Mitigate PLC Communication Disruptions2026-01-02504/7/2026
PLCs (Programmable Logic Controllers) are critical devices in manufacturing, enabling the functioning of machinery and the transmission of build data to other systems in a production facility. Thus, maintaining uptime of these devices is crucial for ensuring that a facility can keep its line running, as even a few minutes of downtime can cost a company thousands in lost units and revenue. One particular pain point that causes downtime is broken communication between the devices and downstream applications, especially those that track orders and traceability. While advances in computing and digital technology have enabled the quick detection of lost signaling and the quick restoration of communication channels, there is much work left to be done in this realm. Besides causing downtime, an incident disrupts the flow of the line, leading to significant effort to restore normal production flow, even after resolution of the incident. In addition, the outage and the post-incident recovery
Jan, Jonathan, Preston, Joshua
NASA Tech Briefs: April 202626AERP044/2/2026
Leonardo DRS Expands Production Capacity to Advance Naval Power, Sensors, and AI-Driven Mission Systems Success at Sea: NIWC Atlantic Uncrewed Surface Vessel Completes Fastest Transatlantic Crossing High‑Speed Spindles Unlock Five‑Axis Machining Innovation with Smaller Tools Why CFD is Stuck in the File Era Accurate and Resilient GNSS Timing Modules for Critical Infrastructure Undetectable Ship-to-Ship Laser Communications EP40: Structural Epoxy Used for Steel Bonding in Marine Applications Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry Vortex Research to Solve Aviation's Efficiency Tradeoff with Active Strakes A research team developed a smart strake system that dynamically adapts to flight conditions, showing a promising drag reduction in the wind tunnel with respect to passive strakes. This
Leonardo DRS Expands Production Capacity to Advance Naval Power, Sensors, and AI-Driven Mission Systems26AERP04_014/1/2026
Leonardo DRS has opened a new naval power and propulsion manufacturing and testing facility in Charleston, South Carolina, expanding its role in delivering next generation electric propulsion, integrated power systems, and high energy payload support for U.S. Navy surface and undersea platforms. The 140,000 square foot site consolidates advanced manufacturing, final assembly, and high fidelity testing for electric power conversion and propulsion systems, while also supporting naval steam turbine design, production, and subsystem integration for programs including the Columbia class ballistic missile submarine. A representative for Leonardo's Naval Power Systems business unit provided emailed statements with details about the type of advanced manufacturing the company will deploy at the new facility.
Scout CEO: 160K reservations, no unsolvable problems26AUTP04_094/1/2026
Despite reports saying the company could delay production until 2028 due to technical challenges, the CEO of Scout Motors, the made-in-America electric SUV and truck startup, said the plan is still to have prototype cars come “down the line” in 2027 with customer vehicles following “thereafter.” Scott Keogh said life as a startup company producing electric vehicles from a clean sheet is a life of on-the-fly adjustments. “There are technical challenges every minute of every day,” he said at an Automotive Press Association briefing at the company's Novi, Michigan tech and engineering site. “But there are no defining ‘oh my god’ technical challenges that can't be solved.”
Clonts, Chris
SUPPLIER EYE26AUTP04_054/1/2026
This will be my last column for SAE Automotive Engineering after an 11-year run. Don't worry, I'm not going anywhere, just taking a monthly column off my plate to enable more time to spend with my grandson and focus on other passions. While I have been a forecaster for nearly four decades, writing a column for an external publication was always an important outlet for ideas. An opportunity to outline a trend, event, or development that would change the fortunes of our industry, specifically for suppliers. While OEMs get the headlines and the accolades, supporting the unsung supply base has been Job 1 in my book.
Business Reliability Growth for Automotive Engineering, Volume 4R-5522/17/2026
In a world where every business process is under pressure to perform faster, safer, and more reliably, this book delivers a powerful roadmap for sustained operational excellence. Centered on the proven methodology of Design of Experiments (DOE), it shows how organizations can move beyond reactive problem-solving to systematic reliability growth. From well-defined standard operating practices to management-level decision-making, the book connects strategy, data, and execution to create repeatable, measurable results across the enterprise. Readers are guided through practical, real-world applications of DOE, from selecting the right factors and levels to executing robust experiments, analyzing outcomes, validating solutions, and continuously monitoring performance. Each chapter translates complex statistical and engineering concepts into actionable business value, helping teams improve quality, reduce waste, and increase return on investment. Key capabilities explored in this book
Chiang, Young J.
Q&A26TOFHP02_112/1/2026
The advanced construction equipment packing the convention center halls and surrounding lots will understandably be the stars of the triennial CONEXPO trade show, taking place March 3-7 in Las Vegas. But the latest technologies in fluid power and motion control that help those machines operate efficiently will also command attention from showgoers. The Bosch Rexroth mobile hydraulics team will be on-site in a joint booth with partner HydraForce (Booth S80245), showcasing their current product portfolio. Rafael Cardoso, Bosch Rexroth engineering manager, mobile systems and software, expects to have conversations about advanced control and automation, “focused on the demand for smarter, software-driven control strategies that enhance precision, productivity, downtime reduction and operator assistance features.”
Gehm, Ryan
New Material Significantly Enhances Green Hydrogen Production EfficiencyTBMG-545612/1/2026
Green hydrogen, produced through water electrolysis, is a next-generation eco-friendly energy source as it does not generate pollutants like carbon dioxide during production. Catalysts play a crucial role in the water electrolysis process, splitting water into hydrogen and oxygen. The efficiency of green hydrogen production largely depends on the performance of these catalysts. Therefore, the commercialization of green hydrogen hinges on the development of cost-effective catalysts capable of maintaining high performance over extended periods.
Measurement Uncertainty and Consumer RiskAIR6553 (Current)1/28/2026
This document addresses measurement uncertainty and consumer risk as they relate to AS8879 thread inspection. It describes the rationale, theory and methodology used to generate the technical content of the AS5870. The document describes how to calculate measurement consumer risk. It documents all of the calculation methods which industry employs today to calculate what is commonly called measurement uncertainty (Appendices A, B, C, D, E and F). These, in turn, are used to calculate measurement uncertainty ratios which are required inputs to calculate measurement consumer risk. Users of this document can apply the information described herein for the evaluation of the capability of their measurements based on the measurement consumer risk. It involves the analysis of the measurement (product) distribution and biases of both the product and measurement system distributions. It protects the consumer from the worst case distribution results.
E-25 General Standards for Aerospace and Propulsion Systems
Fundamentals of Sustainable Aviation FuelsR-5471/22/2026
As global energy demands rise and environmental challenges intensify, the aviation industry faces a critical need to redefine how it powers the skies. Fundamentals of Sustainable Aviation Fuels presents a comprehensive, research-driven exploration of the transition from fossil-based fuels to renewable alternatives that promise to reshape the future of air transportation. This book bridges the gap between academic knowledge and industrial application, offering a detailed overview of the science, technology, and policy driving the adoption of Sustainable Aviation Fuels (SAFs). From understanding feedstocks and conversion pathways to evaluating production technologies, emissions performance, and life-cycle impacts, the text equips readers with a holistic understanding of SAFs within today’s global energy landscape. Across five insightful chapters, readers will find a clear roadmap: the evolution and importance of SAFs; production methods and technological foundations; environmental
Yilmaz, Nadir
Automotive Cybersecurity Measures in ECU Production2026-26-06281/16/2026
Modern vehicles use a network of Electronic Control Units (ECUs) that transmit over thousands of signals. The production of these ECUs is fraught with cybersecurity challenges that can lead to significant vulnerabilities, which pose risks not only to the suppliers but also to Original Equipment Manufacturers (OEMs) and end users. The automotive industry increasingly relies on sophisticated electronic systems but there is a lack of standardized approach to ensure implementation of robust cybersecurity measures during ECU production. It is imperative to establish effective safeguards against potential threats to ensure vehicle and passenger safety. This paper proposes a comprehensive approach to enhancing cybersecurity in ECU production. Key measures include the activation of cybersecurity protections in production units, secure flashing at plant and memory upload process, effective plant password generation, and securing the debug interface to prevent unauthorized access. By
Kulanthaisamy, Nagarajan, M S, Tejaswini, Sankar, Ganesh
Post-EOL Cybersecurity Validation for Automotive Production Units2026-26-06081/16/2026
ISO/SAE 21434 emphasizes comprehensive cybersecurity risk management throughout the automotive lifecycle. However, specific guidance on validating cybersecurity measures at the production level remains limited. This paper addresses the gap in production-stage validation, particularly after End-of-Line (EOL) flashing, which includes configurations of security hardware and software protection (e.g., hardware register configuration, Debug and P-flash password settings etc.) Current automotive cybersecurity validation methods, despite adherence to ISO/SAE 21434, lack specific procedures for the production stage. The existing system-level validation using the ASPICE V-model (e.g., SWE.6, SYS.5) does not ensure the integrity and functionality of cybersecurity features in the final manufactured unit post-EOL flashing. This gap poses a risk of vulnerabilities being introduced during the EOL process, compromising critical security measures. To mitigate the cybersecurity risks in production
Chakraborty, Sucheta, Kulanthaisamy, Nagarajan, Sankar, Ganesh
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-02811/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
Transforming Manufacturing: Increasing Throughput and Reducing Production Complexity with Digital Twins2026-26-04491/16/2026
This paper presents a bidirectional digital twin developed for the Fischertechnik Smart Factory Kit, enabling real-time simulation and validation of production line modifications prior to actual deployment. The digital twin integrates with a Siemens Programmable Logic Controller (PLC) to mirror real-world operations, capturing live production data and visualizing key factory parameters, such as product, process, and resource metrics within a 3D environment. Engineers can test various optimization scenarios by adjusting robot speed and path, conveyor speeds, part & process sequences, and modifying equipment layout sizes to enhance efficiency. Based on the optimization scenarios, the best-performing configurations are identified using metrics such as throughput, cycle time, and resource utilization. Once validated, these changes are directly deployed to the PLC, ensuring seamless implementation. Beyond capacity optimization, this solution enhances overall production efficiency by
Kumar, Rahul, Singh, Randhir
Transforming Gear Manufacturing: A Deep Learning Approach to Quality Prediction2026-26-06461/16/2026
The automotive industry is rapidly transitioning towards Industry 4.0, transforming vehicle manufacturing. To achieve a lower carbon footprint, it is crucial to minimize raw material wastage and energy consumption. Reducing component wastage, lead time, and automating gear manufacturing are key areas. Gear micro-geometry inspection is vital, as variations affect service life and NVH (Noise, Vibration, Harshness). Despite standards for permissible errors, manual evaluation of gear microgeometry inspection is often needed. This subjective evaluation approach will have a possibility that a gear with undesired variations gets assembled into the product. These issues can be detected during NVH testing, leading to replacement of part and re-assembly thus increasing lead time. This generates a need for an automated system which could reduce the human intervention and perform gear inspection. The research aims to develop a deep learning-based model to eliminate the ambiguity of manual
Ramakrishnan, Gowtham Raj, Baheti, Palash, PR, Vaidyanathan, Durgude, Ranjit, Bathla, Archana, R, Greeshmita, V, Rangarajan
Advanced Defect Detection Techniques Using AI, CAD Data, and Computer Vision2026-26-06441/16/2026
In area of modern manufacturing, ensuring product quality and minimizing defects are utmost important for maintaining competitive advantage and customer satisfaction. This paper presents an innovative approach to detect defect by leveraging Artificial Intelligence (AI) models trained using Computer-Aided Design (CAD) data. Traditional defect detection methods often rely on physical inspection, which can be time-consuming and prone to human error. The conventional method of developing an AI model requires a physical part data, By utilizing CAD data, the time to develop an AI model and implementing it to production line station can be saved drastically. This approach involves the use of AI algorithms trained on CAD models to detect and classify defects in real-time. The field trial results demonstrate the effectiveness of this approach in various industrial applications, highlighting its potential to revolutionize defect detection in manufacturing.
Kulkarni, Prasad Ramesh, Sahu, Dilip, Joshi, Chandrashekhar, Khatavkar, Akshay, Poddar, Shivani, Deep, Amar
The Viability of Ammonia in the Automotive Sector: Challenges and Opportunities2026-26-01281/16/2026
Ammonia has emerged as a promising alternative fuel for transportation because of its high energy density (NH3 has more hydrogen than propane in a similar size tank), simple and carbon-free combustion, and potential to produce sustainably. This paper investigates the feasibility of using ammonia as fuel for internal combustion engines (ICE) and fuel cells in automotive applications. In many ways, ammonia captures these benefits by being produced from renewable energies and having the potential to reduce reliance on fossil fuels. There are significant drawbacks of ammonia however, such as its decreased energy content per unit volume, NOx emissions potential, and necessary engine adaptations. This paper discusses the combustion characteristics of ammonia and how it functions in typical ICE's as well as new fuel cell technology, and the necessary infrastructure to produce, store, and distribute ammonia for automotive applications. The study compares operations to conventional fuels
Jadhav, Ajinkya, Bandyopadhyay, Debjyoti, Sutar, Prasanna S, Sonawane, Shailesh Balkrishna, Rairikar, Sandeep D, Thipse, Sukrut S
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-05011/16/2026
Manufacturing tolerances play a critical role in the quality and functionality of components, particularly those made from rubber. Even slight deviations in dimensions can cause significant issues such as improper fit and reduced performance, leading to increased costs and project delays. This is especially true for rubber grommets, which are nonlinear elastic components commonly used as sealants, gaskets, and insulation covers in automotive and industrial applications. Typically manufactured from EPDM rubber with varying Shore hardness, grommets must maintain precise geometry to ensure sealing integrity and protect adjacent parts. Dimensional inaccuracies can result in failures such as buckling or misalignment, compromising both functionality and durability. This study proposes a digital simulation methodology for early-stage evaluation of grommet robustness, reducing reliance on physical prototypes. Using a stochastic design of experiments (DOE) approach, the influence of critical
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Optimization of the Hood Ro-dip CED Process Through Strategic Support Rod Placement at Multiple Locations for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is new technology used by automotive manufacturers for higher quality corrosion protection in new generation automobiles. This process involves multiple 360-degree rotation of automotive body-in-white (BIW) which exert higher hydrostatic pressure and drag forces on large surface panels of BIW like hood. For maintaining consistent gaps and flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel hood panel while undergoing through this CED process. This study investigates the enhancement of hood structure supports through strategic optimization of support rod placement and quantity within the Ro-dip CED paint shop system. This Paper underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Factory Digitalization Efficiency Improvement through Mechanization of Point Cloud to 3D Modelling2026-26-03071/16/2026
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modelling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize
Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, Fasge, Abhishek
Optimizing Suspension Joint Reliability: Overcoming Bolt Loosening and Torque Variability in Automotive Production2026-26-04921/16/2026
In modern automotive manufacturing, ensuring the integrity of suspension joints under real-world driving conditions is a critical aspect of vehicle safety and performance. These joints endure substantial transverse loads and large vibrations due to irregular road surfaces, dynamic maneuvers, and varying environmental factors. As a result, bolt loosening becomes a significant concern, compromising joint integrity and overall vehicle reliability. This paper delves into the challenges associated with maintaining joint integrity, specifically focusing on pre-load determination, torque application, and production-related issues. The pre-load generated during torquing is the primary factor that ensures a suspension joint remains securely fastened under dynamic road conditions. This pre-load is derived using road load data acquisition (RLDA) inputs, which capture the forces acting on the joint during actual driving scenarios. RLDA inputs provide critical insights into the forces experienced
Kumar, Sabeesh, Vasant Kumar, Jesse Daniel, Mishra, Harshit, Senthil Raja, T, Nayak, Bhargav, M, Sudhan, Namani, Prasad, Vibhute, Shekhar
Optimization of Global and Local Formability Properties through Nb Microalloying2026-26-03031/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-03011/16/2026
This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts suitable for
Chava, Seshadri Reddy, Singh, Prakhar, Dhanajkar, Narendra, Roy, Amlan, Raju, Gokul
Automated Evaluation of Drive File Simulation Accuracy2026-26-05281/16/2026
In the area of structural durability testing using servo hydraulic actuators, developing drive files for the actuators is a major step. Testing outcomes depend on ensuring the simulation accuracy of each drive file. These drive files are developed in an iterative process for different test track surfaces at different road and load combinations till the time we achieved better correlation. Evaluation of simulation accuracy of the drive files is an extensive manual review process making it time-consuming and resource-intensive. To address this challenge, an application has been develop to automate the comparison of actuator signals with predefined target signal files. This tool enables quick and accurate analysis of each drive file in a test run facilitating a comprehensive review of signal deviations. Each test run is having thousands of drive files based on road-load mix and actuator settings. This application helped us in significantly optimizing the simulation workflow by reducing
Soni, Yash, Katake, Vrishali, Mullapudi, Dattatreyudu, Chaskar, Mithun
Biodiesel Production via Homogeneous Route (KOH) and Heterogeneous Route (K 2 O/Nb 2 O 5 )2025-36-011612/18/2025
Biodiesel, a renewable biofuel obtained from vegetable oils or animal fats, has emerged as a sustainable alternative to fossil fuels. This fuel has stood out for its ability to reduce greenhouse gas emissions, helping to mitigate environmental impacts. Biodiesel is produced by reacting oil with an alcohol in the presence of a catalyst, which can be homogeneous or heterogeneous. Heterogeneous catalysis has advantages such as ease of separation, greater tolerance to oils with a high fatty acid content and the possibility of reusing the catalyst, which reduces costs and minimizes waste generation. Among the various heterogeneous catalysts available, niobium-based compounds stand out. The use of niobium-based catalysts is advantageous due to the vast reserves of this element in Brazil, guaranteeing autonomy in production and strengthening the national biofuels industry. This work investigated the production of biodiesel from soybean oil using the homogeneous and heterogeneous
Coelho, Gabriella Vilela, Alvarez, Carlos Eduardo Castilla, Ribeiro, Jessica Oliveira Notório
Application of a Process Mining Tool for Three-Way Match Analysis in the Procure-to-Pay Process of a Multinational Auto Parts Company2025-36-023612/18/2025
Process mining emerges as a very important tool in the automotive industry to improve processes and increase efficiency. Its use allows the identification of bottlenecks and opportunities for improvement in production processes, contributing to increased productivity and cost reduction. This article aimed to evaluate the benefits of applying the Process Mining tool by conducting a Three-way match analysis in the Procure-to-pay (PTP) process of a company in the auto parts sector, seeking to identify opportunities for improvement. Analysis using process mining in PTP of the organization allowed us to identify significant number of cases of price discrepancies were observed in relation to orders related to services, being 2.5 times higher than orders related to materials. Additionally, quantity discrepancies represented 24% of the cases analyzed, compared to only 1.5% of price discrepancies. Of the materials involved in these price discrepancies, approximately 63% were not registered in
Rosa da Silva, Petterson Maxwell, Campos, Renato de, Franco, Bruno Chaves
Tire-Tooling Production and Maintenance Monitoring within a Fully Integrated Ecosystem2025-36-001912/18/2025
The work presented here was developed within the scope of the Tire-Tooling Benchmark Project – Mover – FUNDEP – Line IV – in response to demands from the tire manufacturing sector for solutions to monitor tire molds. This study presented the development and validation of an embedded device that integrates RFID technology, wireless communication (LoRa and Wi-Fi), and local processing via an ESP32 microcontroller. The system was capable of collecting and processing data related to mold lifecycle, such as usage cycles, inspections, and maintenance activities, enabling predictive maintenance strategies. A functional prototype was successfully built and tested, validating reliable cycle readings, stable communication with a remote database, and consistent embedded logic. Based on these results, a custom Printed Circuit Board (PCB) was designed, focusing on robustness, compactness, and industrial applicability. Although the PCB has not yet been fabricated or tested in the production
Pivetta, Italo Meneguello, Cecone, Eduardo Christiano, Del Conte, Erik Gustavo
Development of a Localized Heat Treatment Route for Stamped Automotive Parts2025-36-008912/18/2025
The increasing demand for sustainable and space-efficient manufacturing solutions in the automotive industry has driven the search for alternative processes to conventional hot stamping. This study proposes a novel localized heat treatment technique based on Joule heating, aiming to reduce the physical footprint of production equipment, simplify the thermal processing of structural components, and minimize the carbon footprint of the process. The method consists of cold stamping followed by localized austenitization of 22MnB5 steel using electrically powered copper electrodes, eliminating the need for large-scale gas-fired furnaces. The process is particularly advantageous in the Brazilian context, where the electric energy matrix is predominantly hydroelectric, contributing to lower CO2 emissions. Experimental trials were conducted using a Gleeble® thermomechanical simulator to optimize thermal cycle parameters (heating rate, austenitization temperature, and soaking time) ensuring the
Santana, Jessica, Curti, Gustavo, Lima, Tiago, Sarmento, Matheus, Callegari, Bruna, Folle, Luis
Case Study: Nanocomposite-Based 3D Printing and the Implementation of Quality Management to Enhance the Production of Automotive Parts2025-36-020612/18/2025
Additive manufacturing is one of the pillars of technologies of the industry 4.0 and enables rapid prototyping, testing of new materials, and customized manufacturing of parts with personalized design. Poly(lactic acid) (PLA) is a bio-based and biodegradable polymer that is used in packaging, medical applications, and consumer goods. However, it presents low mechanical strength and thermal stability, which limits its use in automotive parts. The use of reinforcement materials such as cellulose nanofibers (CNF) aim to increase the mechanical strength and thermal stability of PLA without reducing its ecological appeal. However, the addition of nanofibers in the 3D printing process can lead to reproducibility problems and constant clogging of the extruder nozzle due to the material’s lower printability. These difficulties may restrict its application to industrial processes due to reduced productivity. To address the challenges in the production of automotive parts with PLA/CNF composites
Oliveira, Vinícius, Horiuchi, Lucas Nao, Gonçalves, Ana Paula, Souza, Mariana, Polkowski, Rodrigo
Application of Lean Manufacturing Tools to Reduce Defect Incidence in Tire Production2025-36-002112/18/2025
The continuous pursuit of operational excellence in the tire manufacturing industry necessitates structured approaches to minimize production defects, improve resource utilization, and enhance product reliability. This study presents a comprehensive case study focused on the implementation of Lean Manufacturing tools within a high-volume production facility specialized in truck and bus radial (TBR) tires. The production line under investigation exhibited recurring defects on the sidewall region of the cured tires, referred to as defect F1, stemming primarily from condensation phenomena and steam management inefficiencies during the curing process. A detailed root cause analysis was conducted through structured brainstorming sessions, Ishikawa diagrams, and the 5 Whys method, revealing multiple converging causes including excessive internal pressure, improper drainage angles, degraded sealing interfaces, and inadequate vapor shielding. In response, a corrective action plan was deployed
Filho, William Manjud Maluf, Yoshimura, Sofia Lucas, Marques, Ana Sung, Sousa, Julia Zanardo, Siqueira, Gonçalo, Alves, Marcelo Augusto Leal, Ferreira, Wallace Gusmão
Review of the Potential for Utilizing Organic Waste for Biogas Production in Latin American Countries2025-36-008312/18/2025
Environmental agreements and the urgent need to mitigate greenhouse gas emissions have positioned biogas as a sustainable alternative for bioenergy production. Biogas is a highly versatile fuel that can be used for heat and electricity generation, as well as a substitute for fossil fuels. However, its contribution to the global energy matrix remains limited. This study presents a literature search aimed at assessing the potential for biogas and bioenergy production in Latin American countries, with an emphasis on agro-industrial, agricultural, and urban waste sources. This source was conducted using articles retrieved from the CAPES Journals Portal. Based on the findings, Brazil stands out due to its extensive agro-industrial sector, while countries such as Argentina, Colombia, and Mexico also offer substantial opportunities which biogas could meet a significant share of regional energy demand. The review showed that sugarcane residues in Colombia could replace up to 44% of gasoline
Rodrigues, Jônatas Soares, Moreira, Thiago Augusto Araújo, Souza Pereira, Felipe Augusto de, Castro, Daniel Enrique
Transport Alternative for Harvested Sugarcane with 50% Reduction in Fuel Consumption (Diesel)2025-36-007612/18/2025
Agrícola Cana Caiana and Grunner have developed an innovative vehicle for sugarcane harvesting, focused on reducing fuel consumption. This optimization is vital and relevant for similar operations in the largest global producers: Brazil (724 mi t - 37%), India (439 mi t - 22%), China (103 mi t - 5.3%), Thailand (92 mi t - 4.7%), Pakistan (88 mi t - 4.5%), Mexico (55 mi t - 2.8%), Colombia (35 mi t - 1.8%), Indonesia (32 mi t - 1.6%), USA (31 mi t - 1.6%), and Australia (28 mi t - 1.4%). In Brazil, São Paulo leads with 383.4 mi t (54.1% of the 23/24 harvest), followed by Minas Gerais (81.3 mi t). This innovative agricultural machinery, a result of the owners' experience, has already sold over a thousand units, proving its impact on the efficiency of the sugar-alcohol sector. The Belei family's expertise generated this solution that optimizes resources and increases harvesting productivity, with the potential to advance sustainability and profitability globally, driving agricultural
Ferreira, Antonio Eustáquio Sirolli
Manufacturing Optimization of Automotive Coatings: Applying Lean Six Sigma to Improve Filling Line Performance2025-36-001112/18/2025
This study presents the results of applying a Lean Six Sigma-based analytical approach to optimize the manufacturing of automotive coatings, specifically in a PU primer filling process. Through production flow mapping and the Define, Measure, Analyze, Improve, and Control (DMAIC) methodology, unplanned stoppages in the filling line were significantly reduced, addressing critical inefficiencies in automotive coating production. The research was driven by the need to enhance manufacturing productivity and ensure process reliability in the production of coatings used in the automotive sector. To achieve this, Quality Management tools, such as Pareto Analysis and the Cause-and-Effect Diagram, along with Lean Manufacturing techniques, including Kaizen Blitz, were applied. These methods facilitated the identification and mitigation of key causes of unplanned downtime, improving process efficiency and reliability. The results demonstrated a significant reduction in downtime, enhanced
Filho, William Manjud Maluf, Rodrigues, Mateus Ferreira, Carriero, Emily Amaral, Yoshimura, Sofia Lucas, Marini, Vinicius Kaster, Siqueira, Gonçalo, Alves, Marcelo Augusto Leal
Study on the Mechanical Properties of a High-Strength Aluminum Alloy Profiles2025-99-033212/17/2025
Compared to steel, aluminum alloy has the advantages of light weight, high specific strength, corrosion resistance, and easy processing, and is widely used in structures such as aviation, construction, bridges, and offshore oil platforms. All along, Chinese construction aluminum profiles have been produced according to the GB/T5237-XXXX standard, which is determined based on the mechanical performance requirements of doors and windows and the actual processing of aluminum profiles. There are many problems. The author of this article has developed a new product 6063-T56, which has a tensile strength of 240-260Mpa and an elongation rate of not less than 8%, surpassing the latest technology level in Europe. It has been promoted and applied to the aluminum profile production industry in China, improving product performance, reducing production costs, improving production efficiency, and meeting the requirements of the "Aluminum Alloy Doors and Windows Standard" GB/T8478-2020, making
Qiao, Zhou
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