Articles tagged with "lightweight-materials"
Tesla Is Missing The Massless EV Battery Boat
The article discusses the emerging trend of cell-to-body battery architecture in electric vehicles (EVs), highlighting how companies like BYD and Volvo are pioneering this technology while Tesla lags behind. Cell-to-body design integrates battery cells directly into the vehicle’s chassis, eliminating the need for traditional battery packs. This innovation reduces vehicle weight, cuts costs, frees up space, and simplifies assembly, leading to improved EV performance and efficiency. BYD, a Chinese automaker, has been an early and rapid adopter of this approach, contributing to its rising EV sales in Europe. Academic research, particularly from Chalmers University in Sweden, has been advancing the concept of a "massless EV battery" by using carbon fiber as a structural material in battery cells. This multifunctional carbon fiber replaces conventional aluminum foil in electrodes, providing increased stiffness, energy density, and faster charging capabilities. Funded by Swedish agencies, this research aims to create lighter, more efficient batteries that serve both as energy storage and structural components, further
energyelectric-vehiclesbattery-technologycell-to-body-architecturecarbon-fiberlightweight-materialssustainable-energyPhotos: Italy’s 131-foot aluminum superyacht takes supercar cues for faster cruising
The Ceccarelli 40 is a 131-foot aluminum superyacht unveiled by Italian builder Tuxedo Yachting House, marking the company's largest and most ambitious project to date. This launch represents a significant leap for the young, family-run shipyard, which previously produced yachts between 45 and 65 feet. The yacht blends traditional Italian elegance with cutting-edge technology and design, featuring a semi-displacement hull optimized for speed and efficiency. Powered by twin MAN V-12 engines, the Ceccarelli 40 can exceed 18 knots and cruise comfortably at 15 knots, with an option for hybrid propulsion. Its exterior styling draws inspiration from high-performance supercars, incorporating elements like a sharply angled windshield and a roll bar resembling a rear spoiler to create a dynamic yet elegant profile. The Ceccarelli family has a long history in Italian yacht building, dating back to the 1960s, with a pioneering focus on aluminum construction that enhances performance and reduces weight. Today
aluminumsuperyachtmaterialsyacht-constructionlightweight-materialsItalian-shipbuildingmarine-engineeringAerogels and the engineering limits of empty space
Aerogels are an advanced class of ultralight materials composed of up to 99.8% air, making them some of the lightest solids known. Silica-based aerogels are common, while graphene aerogels can be even lighter than air, with densities as low as 0.16 kg/m³. Despite their extreme lightness and porous, semi-transparent appearance—earning nicknames like “frozen smoke” or “solid clouds”—aerogels exhibit notable mechanical resilience and can absorb large amounts of substances, such as oil. First developed in 1931 by Samuel Kistler, aerogels have since been applied in diverse fields including space exploration, construction, energy systems, and industrial insulation, influencing modern engineering approaches to lightweight, high-performance materials. The production of aerogels involves replacing the liquid in a gel with gas while preserving the solid framework. Starting from a gel precursor, chemical reactions form a semi-solid gel with liquid-filled pores on the nanoscale
materialsaerogelsadvanced-materialslightweight-materialsinsulationnanomaterialsgraphene-aerogelsPhoto: Honda unveils solar powered towable camper that weighs under 1,500 pounds
In January 2026, Honda introduced the Base Station Prototype, a lightweight, solar-powered towable camper designed to broaden access to camping by enabling towing with most vehicles under 1,500 pounds. Constructed with a fiberglass shell and aluminum chassis, the camper is compatible with compact SUVs like the Honda CR-V and upcoming electric models, eliminating the need for heavy-duty trucks. The modular design includes features such as a pop-up roof for increased headroom and sleeping space, a slide-out kitchen, and removable window modules that can be swapped for amenities like an air conditioner or outdoor shower. The interior maximizes functionality within a compact footprint, offering convertible furniture that sleeps up to four people, large windows for natural light, and storage space suitable for equipment like bicycles. Powered by solar panels and a lithium battery, the Base Station supports off-grid camping and can manage its systems via an onboard touchscreen or mobile app. While still a prototype without a confirmed release date or price, Honda is reportedly considering production, marking
energysolar-powerlightweight-materialselectric-vehiclesmodular-designoff-grid-campinglithium-batteryRenault Filante Record 2025 Raises The Efficiency Bar For Electric Cars - CleanTechnica
The Renault Filante Record 2025 is an experimental electric car designed to push the boundaries of efficiency rather than speed, reflecting a shift in automotive priorities toward intelligent travel distance. Drawing on Renault’s extensive experience in Formula One racing since 1977, where aerodynamic efficiency is meticulously optimized, the Filante Record leverages advanced design techniques and materials to minimize energy consumption. The project involved close collaboration with Ligier for vehicle construction and Michelin for ultra-low rolling resistance tires, emphasizing real-world testing of technical choices on energy use. A key focus of the Filante Record 2025 is weight reduction, inspired by Colin Chapman’s philosophy of “simplify then add lightness.” With batteries constituting over half the vehicle’s mass, Renault aimed to keep the car’s weight around 1,000 kg (2,204 lb) using carbon fiber, composites, and optimized structures. Aerodynamic efficiency was also critical, measured by the SCx value (frontal area times drag coefficient). Initial wind tunnel tests
electric-vehiclesenergy-efficiencyRenault-Filante-Recordbattery-technologylightweight-materialsaerodynamicssustainable-mobilityPhotos: Renault EV hits 626 miles on single charge, sets new efficiency record
Renault achieved a significant electric vehicle milestone at the end of 2025 with its single-seater prototype, the Filante Record 2025, which traveled 626 miles (1,008 km) on a single charge. The test, conducted at a Moroccan high-speed proving ground, lasted under 10 hours with an average speed of 102 km/h (63 mph). Remarkably, the car retained 11 percent battery capacity at the finish, suggesting a potential total range of up to 673 miles (1,083 km). The prototype’s design drew inspiration from historic Renault record-setters and incorporated advanced aerodynamic refinements, lightweight materials like carbon fiber and aluminum alloys, and specially developed low-drag tires to maximize efficiency. Powered by an 87 kWh battery pack—identical in capacity to that of Renault’s Scenic E-Tech crossover—the Filante Record achieved exceptional energy efficiency, consuming just 7.8 kWh/100 km at highway speeds, compared to 14.1
electric-vehiclesbattery-technologyenergy-efficiencylightweight-materialscarbon-fiberaerodynamicsautomotive-innovationHAP-alpha solar aircraft clears ground tests, preps for flight trials
Germany’s German Aerospace Center (DLR) has achieved a significant milestone with its HAP-alpha solar-powered unmanned aerial vehicle (UAV), designed for long-duration, high-altitude Earth observation missions. The ultra-light aircraft, weighing just 304 lbs (138 kg) with an 88-foot (27-meter) wingspan, completed a comprehensive series of ground tests at the National Experimental Test Center for Unmanned Aircraft Systems in Cochstedt by autumn 2025. These tests verified the functionality of its systems, including lightweight high-resolution cameras and synthetic aperture radar, and confirmed its structural stability through static vibration testing. The HAP-alpha UAV is engineered to fly at very low speeds to conserve power, relying on solar cells to continuously supply energy for propulsion and onboard systems. During ground trials, it operated solely on onboard power and responded to commands via radio link, simulating real flight conditions. The aircraft was supported to prevent wing and tail flexing and used a patented mechanism for controlled automatic takeoff
solar-energyunmanned-aerial-vehiclehigh-altitude-platformEarth-observationlightweight-materialsrenewable-energydrone-technologyPhotos: Encor reveals carbon Esprit restomod with reworked V8 power and only 50 units
Encor Designs has unveiled the Series I, a restomod of the 1975 Lotus Esprit that blends classic design with modern engineering and performance. Limited to just 50 handcrafted units, the Series I features a single-piece carbon-fiber body replacing the original fiberglass, delivering sharper edges and improved aerodynamics. The car is powered by a reworked Type 918 V8 engine producing 400 horsepower and 350 lb-ft of torque, paired with a strengthened five-speed Quaife manual transmission. Modern electronics, including a new ECU and keyless entry, enhance reliability and usability while preserving the analog driving experience. The interior maintains the original Esprit’s character with updated materials such as billet aluminum and carbon fiber, combined with contemporary amenities like a touchscreen and 360-degree parking camera. Suspension and braking systems have been upgraded with sport uprights, Bilstein dampers, Eibach springs, and AP Racing brakes, while hydraulic steering is tuned for precision. The car’s weight is kept under 2
materialscarbon-fiberautomotive-engineeringlightweight-materialscomposite-materialsenergy-efficiencyautomotive-technologyChina's BYD, Hantek launch 'World-first' one-piece aluminium EV frame
Chinese manufacturer Hantek has developed a groundbreaking one-piece aluminum frame for electric vehicles (EVs), marking a significant advancement in large aluminum casting technology. The frame, covering about 45 square feet with wall thickness varying from 0.16 to 1.97 inches (a thickness ratio exceeding 12:1), overcomes longstanding challenges in producing ultra-large, thin-walled parts through low-pressure casting. Unlike traditional all-aluminum vehicle frames, which are assembled from numerous smaller parts joined by welding or riveting—introducing complexity, cost, and structural weak points—Hantek’s integrated casting method creates a single, robust frame. This innovation enhances body rigidity, torsional stiffness, and crash performance by optimizing force distribution and eliminating joint-related vulnerabilities. This new casting process represents a major step forward for China’s EV manufacturing, potentially reshaping how large vehicle frames are designed and produced by offering a more efficient, integrated alternative to multi-part assemblies. The frame is featured in the BYD Yangwang
electric-vehiclesaluminum-framelightweight-materialscasting-technologyautomotive-manufacturingBYDstructural-componentsOrigami-inspired design by 14-year-old supports 10,000× its own mass
A 14-year-old student from New York City, Miles Wu, won a USD 25,000 prize at the Thermo Fisher Scientific ASCEND Award in October 2025 for creating an origami design based on the Miura-ori fold that can support over 10,000 times its own weight. Wu tested 54 variations of the Miura-ori fold—altering parallelogram heights, widths, fold angles, and paper weights—and found that smaller panels with steeper angles offered the greatest strength and resilience. Surprisingly, standard copy paper outperformed heavier cardstock in strength-to-weight ratio. His strongest design could theoretically hold the equivalent weight of a New York City taxi cab supporting over 4,000 elephants. Inspired by a six-year passion for origami, Wu aims to apply his findings to develop lightweight, deployable shelters for disaster relief. His project involved rigorous testing, including using 50-pound exercise weights to measure load capacity accurately. Selected from nearly 2,000 applicants
materialsorigami-designstructural-strengthlightweight-materialsdeployable-sheltersphysicsMiura-ori-foldGAC T9 and Guangzhou’s Shift to BEV Trucks - CleanTechnica
The article provides an on-the-ground perspective from Guangzhou, highlighting the current state and recent developments in the electrification of heavy trucks, particularly focusing on local automaker GAC (Guangzhou Automobile Corporation). While passenger cars in Guangzhou have largely transitioned to New Energy Vehicles (NEVs) with about 80% featuring green plates, heavy trucks still predominantly run on diesel, especially those from GAC’s joint ventures with Toyota and its subsidiary Hino. This lag in electrification is attributed to Toyota’s slower EV adoption. However, a significant shift occurred after GAC acquired Toyota’s stake in Hino last year, forming GAC New Energy Commercial Vehicle Co., Ltd., which transitioned its commercial vehicles from diesel to fully electric powertrains. At the Auto Guangzhou show, GAC unveiled its T9 electric semi-truck, which stands out due to its EV-specific platform and advanced features. The T9 offers a 330 km range with a 400 kWh LFP battery, charging from
energyelectric-vehiclesbattery-technologyGACcommercial-truckslightweight-materialselectric-powertrainPhotos: Longbow’s exclusive 150-unit Speedster debuts lightweight EV with quick pace
British startup Longbow has introduced the Speedster, a lightweight electric sports car emphasizing agility and driver engagement. Developed rapidly within six months, the Speedster features a bonded aluminium chassis and a structural battery integrated directly into the car’s frame, enabling a remarkably low kerb weight of 895 kg (1,973 lbs). This featherweight design prioritizes handling precision and responsiveness over raw power, delivering a 0-62 mph acceleration in 3.5 seconds and a WLTP range of 275 miles from an estimated 60 kWh battery pack. The Speedster’s design blends classic British open-top sports car aesthetics with modern EV elements, focusing on minimalism, airflow, and driver visibility. Longbow’s engineering approach centers on reducing mass through innovative structural solutions rather than relying on large battery capacity, resulting in efficient range and dynamic performance. Production is limited to 150 units, all hand-built in the UK, with pricing starting at £84,995 for the Speedster and a forthcoming closed
electric-vehicleslightweight-materialsbonded-aluminium-chassisstructural-battery-integrationEV-performanceBritish-automotive-engineeringsustainable-energy-storageLight, extremely strong material withstands 932°F temperature, could be useful for aerospace
Researchers at the University of Toronto Engineering have developed a novel lightweight and extremely strong metal matrix composite capable of withstanding temperatures up to 932°F (500°C), making it highly promising for aerospace and other high-performance applications. The material mimics the structure of reinforced concrete on a microscopic scale, featuring a titanium alloy mesh acting as "rebar" surrounded by a matrix composed of aluminum, silicon, magnesium, and embedded alumina and silicon nanoprecipitates. This design, enabled by additive manufacturing and micro-casting techniques, allows precise control over the composite’s microstructure, resulting in exceptional strength and thermal resistance. Testing revealed that the composite exhibits a yield strength of around 700 megapascals at room temperature—significantly higher than typical aluminum matrices—and maintains 300 to 400 megapascals at 500°C, compared to just 5 megapascals for conventional aluminum alloys. This performance rivals medium-range steels but at roughly one-third the weight, addressing a critical limitation of aluminum alloys
materialscomposite-materialsaerospace-materialsmetal-matrix-compositeadditive-manufacturinghigh-temperature-materialslightweight-materialsGerman startup turns race-car carbon tech into ultralight tanks for space rockets
German startup Blackwave, a spin-off from the Technical University of Munich (TUM), has developed ultralight carbon-fiber high-pressure tanks designed for space rockets. These tanks can withstand operating pressures of up to 420 bars and endure aggressive fuels and temperature fluctuations from -50 to 120 degrees Celsius. Originating from race-car carbon-fiber technology, the tanks offer a significant advancement over traditional heavy, spherical steel tanks used in rockets. Their bottle-shaped design is easier to integrate into fuel systems, chemically inert with fuels, and much lighter and more flexible. Founder Bastian Behrens, inspired by his background in race-car components and passion for aerospace, identified that carbon fibers excel under tensile stress, making them ideal for pressure tanks. The ultralight tanks help maintain rocket structural integrity during flight by releasing noble gases from internal secondary tanks to fill empty spaces as primary fuel tanks deplete. This innovation could provide aerospace engineers with greater design freedom and reduce weight, potentially transforming rocket tank design and
materialscarbon-fiberaerospacespace-rocketshigh-pressure-tankslightweight-materialscomposite-materialsChina’s first 3D-printed mini turbojet engine hits Mach 0.75 in tests
China’s state-owned Aero Engine Corporation of China (AECC) has successfully tested its first fully 3D-printed miniature turbojet engine in a solo flight, marking a significant milestone in the country’s independent aviation propulsion development. The ultra-lightweight engine, producing 353 pounds of thrust, powered a target drone to an altitude of 6,000 meters (about 20,000 feet) and reached speeds of Mach 0.75 during a 30-minute flight. The engine operated stably throughout, validating its design, reliability at higher altitudes, and integration with aircraft systems. This test follows an earlier captive-carry flight at 4,000 meters and represents a transition from controlled testing to operational application. The engine’s design leverages a combination of 3D printing and multi-disciplinary topology optimization (TO), a computational method that optimizes material distribution for performance and weight reduction. This approach enables the creation of complex, lightweight structures that traditional manufacturing cannot easily produce. Over three-
3D-printingadditive-manufacturingturbojet-engineaerospace-materialstopology-optimizationlightweight-materialsaviation-technologyLamborghini's new race car with V8 engine offers 641 horsepower
Lamborghini has unveiled the Temerario Super Trofeo concept, a new race car powered by a twin-turbo 4.0-liter V8 engine producing 641 horsepower. Set to debut on tracks in 2027, the Temerario replaces the Huracán Super Trofeo and shares many components with the recently launched Temerario GT3, including its engine and transmission. Designed as a pure, non-hybrid machine, it targets “gentleman racers” seeking a thrilling yet manageable racing experience, offering more power than the GT3 variant but less than the higher-output Temerario model. The car features an aggressive aerodynamic design with sharp canards, a large rear wing, ventilated fenders, and lightweight materials to enhance downforce and handling. Its chassis combines aluminum and carbon fiber with a fully integrated FIA roll cage for safety, complemented by ABS brakes, adjustable traction control, and a six-speed sequential transmission. Inside, Lamborghini introduces innovative interior materials like Dinamica Infinity upholstery, a lightweight
energymaterialsautomotive-technologyrace-car-engineeringlightweight-materialsengine-technologyautomotive-innovationNew metal foam tougher than steel, could make safer cargo tankers
A recent study by researchers at North Carolina State University highlights the exceptional puncture and impact resistance of Composite Metal Foam (CMF), a lightweight material composed of a metallic matrix embedded with hollow spheres. CMF demonstrated the ability to withstand forces that would typically puncture steel railroad tank cars, which are used to transport hazardous materials such as acids, chemicals, petroleum, and liquefied natural gas. The material’s unique structure not only provides high strength and minimal weight but also offers superior heat resistance and insulation compared to steel, making it highly suitable for safety-critical applications in transportation and defense. In rigorous testing, a 30.48-millimeter-thick CMF layer placed on a steel plate prevented a 300,000-pound ram car’s six-inch steel indenter from puncturing the plate, absorbing nearly all the impact energy and causing only minor damage. This contrasted sharply with the significant hole created in the steel plate without CMF protection. The research team also developed a computational model to optimize CM
materialscomposite-metal-foamlightweight-materialspuncture-resistancetransportation-safetyrailroad-tank-carsthermal-insulationOnly 20 made: Exclusive 1500 hp muscle car has serious Bugatti power
Trans Am Worldwide, based in Tallahassee, Florida, has unveiled the 2026 Chevelle 70/SS, a modern restomod that pays homage to the classic 1970 Chevelle Super Sport. The car is offered in three trims—Base, 396 Heritage, and the top-tier 454 LS6X Limited Edition—with the latter boasting a twin-turbocharged 7.4-liter V8 engine producing an impressive 1,500 horsepower. The body panels are crafted from hand-laid carbon fiber, combining lightweight strength with faithful adherence to the original 1970 Chevelle design. The 70/SS emphasizes both performance and drivability, featuring a Magnuson 2650 supercharger, Holley port injection, a Strange 9-inch rear axle, GForce traction management, Viking coil-over suspension, and Michelin Cup 2R tires. The interior blends classic styling cues such as retro gauges and a horseshoe shifter with modern carbon fiber trim, reflecting a bespoke
materialscarbon-fibermuscle-carautomotive-engineeringhigh-performance-enginelightweight-materialsvehicle-manufacturingEx-Tesla engineers build 'Featherweight' EV that weighs just 1973 pounds
British startup Longbow, founded by former Tesla engineers Daniel Davy and Mark Tapscott, has unveiled its first prototype electric vehicle, the Aesthetic Dynamic Demonstrator, in London. The company aims to address the common issue of excessive weight in high-performance EVs by embracing a "Speed of Lightness" philosophy inspired by Lotus founder Colin Chapman’s principle of simplifying and reducing weight. Their debut model, the roofless and windowless Speedster, is positioned as the first-ever "Featherweight Electric Vehicle" (FEV), weighing just 895 kg (1,973 lbs), significantly lighter than typical EVs. Despite its light construction, the Speedster delivers impressive performance, accelerating from 0 to 62 mph in 3.5 seconds and offering a WLTP-rated driving range of 275 miles. This is achieved through innovative engineering, including a unique aluminum chassis, a compact electric motor, and a module-to-chassis battery design that maximizes stiffness while minimizing mass. The Speed
electric-vehicleslightweight-materialsaluminum-chassisEV-performancebattery-technologyautomotive-innovationelectric-sports-carYouTuber builds drone that flies long using only solar power
YouTuber Luke Maximo Bell has developed a solar-powered drone capable of potentially flying indefinitely by harnessing energy from the sun. Bell optimized the drone for maximum efficiency, using lightweight, high-performance components such as the T-Motor Antigravity MN4004 300kv brushless motor, which features an ultra-thin design, reduced weight, minimal energy dissipation, and an advanced cooling system for stability. The drone frame was fully assembled with careful wiring of motors directly to the electronic speed controller (ESC) and flight controller, enabling a streamlined, efficient power system. The drone also incorporates T-Motor NS 18×6 carbon fiber propellers that provide high thrust, efficiency, and durability, contributing to long, stable flight times and improved maneuverability. Bell’s design achieves a remarkable efficiency of 17 grams of lift per watt at takeoff, which is 24 times more efficient than his previous record of 0.7 grams per watt. The drone uses a T-Motor F
dronesolar-powerenergy-efficiencybrushless-motorUAV-technologylightweight-materialsrenewable-energyAudi tests next-gen electric sports car that could replace iconic R8
Audi has begun real-world testing of its Concept C prototype, a next-generation all-electric sports car expected to debut in 2027 that could succeed the iconic R8. Unlike typical show cars, the Concept C has been made street legal in Germany and carries registration plates, marking a significant step toward production. This two-seater roadster combines a compact, lightweight design with a rear-mounted electric motor and battery pack positioned between the seats, achieving a balance reminiscent of traditional mid-engine sports cars. The prototype currently features rear-wheel drive with a top speed around 90 mph, but Audi plans to offer a dual-motor all-wheel-drive system in the production model to enhance grip and acceleration. Visually, the Concept C emphasizes aerodynamic, sporty styling with slim LED lights, a reinterpreted grille, vertical air vents, and a wedge-shaped rear with integrated louvers and taillights. The removable roof panel allows quick conversion from coupe to open-air roadster. Inside, the minimalist cabin features a
electric-vehiclesAudi-Concept-Celectric-sports-carbattery-technologyautomotive-energyelectric-powertrainlightweight-materialsCarbon-built Capricorn 01 Zagato hypercar limited to 19 units
The Capricorn 01 Zagato is a limited-edition hypercar developed by German motorsport supplier Capricorn Group in collaboration with Italian coachbuilder Zagato, with only 19 units to be handbuilt in Germany starting in 2026. Priced at €2.95 million (approximately $3.2 million), the car emphasizes analog purity and mechanical engagement in an era dominated by digital technology. It features a supercharged 5.2-liter V8 engine producing over 900 horsepower, paired with a five-speed manual gearbox, and weighs under 1,200 kilograms. This combination delivers a visceral driving experience rooted in motorsport engineering, including a carbon fiber monocoque chassis, double-wishbone suspension, and adaptive dampers tuned for balance and precision. Design-wise, the Capricorn 01 Zagato stands out for its restrained, sculptural aesthetic that prioritizes aerodynamic efficiency without aggressive visual elements. Signature Zagato design cues such as the double-bubble roof and seamless carbon fiber bodywork create
carbon-fiberhypercarmaterials-engineeringautomotive-materialslightweight-materialscarbon-compositemotorsport-materialsMIT's high strength aluminum alloy can withstand high temperature
Researchers at MIT have developed a novel printable aluminum alloy that is reportedly five times stronger than traditionally manufactured aluminum and can withstand high temperatures. Using a machine learning (ML)-based approach combined with simulations, the team evaluated only 40 possible material compositions—significantly fewer than the over one million combinations typically required—to identify an optimal mix of aluminum and other elements. This alloy exhibits a high volume fraction of small precipitates, which contribute to its enhanced strength, surpassing previous benchmarks including the wrought Al 7075 alloy. The new alloy, produced via 3D printing rather than conventional casting, benefits from rapid solidification that prevents precipitate growth, resulting in superior mechanical properties. After aging at 400 °C for eight hours, the alloy achieves a tensile strength of 395 MPa at room temperature, about 50% stronger than the best-known printable aluminum alloys. The researchers envision applications in lightweight, temperature-resistant components such as jet engine fan blades—traditionally made from heavier and more expensive
materialsaluminum-alloy3D-printinghigh-strength-materialsmachine-learningadditive-manufacturinglightweight-materialsSilent wings: Top 10 electric planes promising fast, quiet journeys
The article "Silent wings: Top 10 electric planes promising fast, quiet journeys" highlights the significant advancements in electric aviation as of 2025, showcasing how electric aircraft are transitioning from experimental prototypes to production-ready models. Driven by improvements in battery technology, lightweight materials, and hybrid propulsion, these aircraft offer cleaner, quieter, and more efficient flight options. The article profiles leading electric planes that exemplify this shift, including the Pipistrel Velis Electro—the world’s first type-certified electric aircraft used primarily for flight training with zero emissions and ultra-quiet operation. Another key model is the Eviation Alice, an all-electric passenger plane designed for regional travel with a nine-passenger capacity and a cruise speed of 253 mph, emphasizing sustainability and efficiency. Other notable aircraft include NASA’s X-57 Maxwell, which, although its program ended in 2024, contributed valuable research on distributed electric propulsion aimed at drastically improving cruise efficiency. Sweden’s Heart Aerospace ES-30 offers a hybrid-electric solution for
energyelectric-aircraftaviation-technologybattery-technologyhybrid-propulsionsustainable-aviationlightweight-materialsDacia Hipster Concept cuts EV emissions by 50% with lighter build
The Dacia Hipster Concept is a minimalist electric vehicle designed to reduce its carbon footprint by 50% compared to current EV models. This ambitious goal is achieved through a lightweight construction that is 20% lighter than the Dacia Spring, extensive use of recycled materials such as Starkle panels and mass-dyed components, and a simplified manufacturing process that minimizes paint layers and production emissions. The car’s compact design includes a smaller battery optimized for urban and suburban driving, balancing sufficient daily range with lower environmental impact from battery production. The exterior features a single body color with only three painted parts, using mass-dyed materials to reduce paint waste and energy consumption. Its blocky yet balanced design maximizes compactness and functionality, with features like a full-width tailgate and integrated rear lights to reduce material use and costs. Inside, the cabin is space-efficient with vertical windows, a transparent roof section, and flexible seating that expands cargo capacity from 70 to 500 liters. The modular YouClip system allows
energyelectric-vehicleslightweight-materialsrecycled-materialssustainable-manufacturingbattery-efficiencycarbon-footprint-reductionUS Specialty EV Maker Automate Manufacturing of Blue Arc EV Truck - CleanTechnica
Blue Arc EV Solutions, the electric vehicle division of The Shyft Group, a North American specialty vehicle manufacturer with over 50 years of experience, has developed a commercial electric delivery van tailored for last-mile logistics. Unlike many competitors, The Shyft Group designed their EV chassis from the ground up to meet specific delivery fleet needs such as driver ergonomics, durability, and operational efficiency. The Blue Arc vans utilize lightweight materials like aluminum and composites, achieve a driving range of over 220 miles, and offer higher payload capacity than traditional delivery vehicles. The design anticipates overnight depot charging, minimizing dependence on public charging infrastructure. The company has secured an initial order for 150 vehicles from a major delivery company, though the client remains unnamed. To support production, The Shyft Group implemented Rockwell Automation’s Plex Smart Manufacturing Platform, an ERP system that digitizes supplier management, inventory tracking, financial monitoring, and production workflows. This digital infrastructure enabled the company to progress from concept to functional prototype in
electric-vehiclesenergymanufacturing-automationsmart-manufacturinglightweight-materialsEV-trucksdigital-manufacturing-platformsDeLorean recreated with drones, lifts off like 'Back to the Future'
Designer Brian Brocken has successfully recreated a full-scale flying DeLorean from the movie Back to the Future, fulfilling a childhood dream by combining detailed replica craftsmanship with advanced drone technology. The car’s body is constructed from lightweight EPS foam reinforced with fiberglass to maintain the iconic styling without excess weight. Using CAD software and CNC-cut foam slices, Brocken precisely assembled the hollow shell, while a custom carbon-fiber tubular frame provides the necessary strength and rigidity for flight, reducing weight to about 2 kg (4.4 lbs) and addressing structural flex issues encountered with earlier aluminum frames. The replica features functional elements true to the film, including retractable, rotating wheels 3D printed from PLA that enable both ground steering and in-flight folding, as well as gullwing doors with hidden 3D-printed hinges that open automatically. Flight stability was enhanced by adding thrust vector control fins under the four powerful drone motors, each paired with 30-inch propellers producing up to 13.5 kg (
roboticsdronescarbon-fiberlightweight-materials3D-printingCAD-designUAV-engineeringSea Lion Prototype ranks among the fastest amphibious cars of its era
The Sea Lion Prototype, designed by Marc Witt and SeaRoader Aquatic, is a rare and innovative amphibious car that debuted in 2012 as one of the fastest dual-mode vehicles of its era. Powered by a Mazda 13B rotary engine paired with a supercharger and Holley carburetor, the 1.3-liter motor uniquely drives both the rear wheels on land and a jet pump in water, eliminating the need for separate propulsion systems. Its lightweight 5052 aluminum alloy body features a monocoque structure for rigidity and corrosion resistance, balancing aerodynamic and hydrodynamic efficiency. A standout feature of the Sea Lion is its shape-shifting suspension, which hydraulically retracts the front wheels and extends side pods to serve as flotation devices and cargo carriers, enhancing stability and speed across land and water. The water propulsion relies on a Berkeley 12 JC jet pump that provides thrust without exposed propellers, improving safety and reducing drag. The cockpit combines conventional driving controls with a joystick
materialsenergyrotary-enginealuminum-alloyjet-propulsionamphibious-vehiclelightweight-materialsScientists map foams for maximum energy absorption and safety
Mechanical engineers at the University of Wisconsin–Madison have developed a novel design framework that significantly streamlines the creation of shock-absorbing foam materials used in protective gear and aerospace applications. Unlike traditional foam design, which focused mainly on maintaining a constant stress plateau and optimizing mechanical properties alone, this new approach simultaneously considers foam thickness, surface area, and mechanical behavior. The researchers found that foams exhibiting nonlinear stress-strain responses can outperform conventional “ideal absorber” foams, especially in compact designs, expanding the design possibilities for energy-absorbing materials. The framework generates a design map based on inputs such as foam thickness, area, and material properties, enabling engineers to customize foams for maximum energy absorption with minimal weight and volume. Demonstrated on vertically aligned carbon nanotube foams, the method allows rapid optimization without extensive trial and error. Freely available online, the framework has broad applicability across various material systems, including metamaterials and soft robotics, and could revolutionize the development of lighter, safer
materialsenergy-absorptionfoam-designshock-absorbing-materialsmetamaterialsprotective-gearlightweight-materialsMotofocker Velocar delivers car comfort with bicycle freedom
The Motofocker Velocar is an innovative three-wheeled human-electric hybrid vehicle designed by Hungarian inventor Máté Fock that blends the efficiency of a bicycle with the comfort and practicality of a car. Constructed from birch plywood and canvas, the Velocar offers weather protection, stability, and cargo space while remaining lightweight and affordable. It features a pedal-electric assist system with speeds up to 25 km/h and does not require a driving licence, making it accessible for commuters, delivery riders, hikers, and people with mobility challenges. The vehicle’s design emphasizes sustainability, repairability, and modularity, with parts that can be easily sourced or replaced. The Velocar’s chassis is made from water- and cooking-resistant birch plywood, chosen for its strength, low cost, and recyclability, while the canvas body and seat provide durable, lightweight weather protection. Its dimensions (115 cm wide, 115 cm tall, 295 cm long) and weight (57.5 kg standard
energyelectric-vehiclehybrid-vehiclesustainable-transportlightweight-materialsplywood-chassispedelecElectric concept car with illuminating fabrics goes 0-62 mph in 2 seconds
The Vauxhall Corsa GSE Vision Gran Turismo is an innovative electric concept car that combines high performance with unique safety and design features. Part of Vauxhall’s GSE performance sub-brand, the vehicle boasts a fully electric powertrain with dual 476hp motors—one on each axle—delivering a combined 800hp and 800Nm of torque. This enables the car to accelerate from 0-62 mph in just two seconds and reach a top speed of 199 mph. Lightweight construction, achieved through extensive use of advanced materials and an 82kWh battery, keeps the car’s weight to 1,170 kg, enhancing its power-to-weight ratio and overall agility. The car will debut physically at the IAA Mobility 2025 in Munich and will be digitally available in the Gran Turismo 7 video game. The concept features a minimalist, racing-inspired interior with a suspended sport seat, six-point seatbelts, and a single head-up display. A standout safety
electric-vehiclesilluminated-fabricslightweight-materialsenergy-storageautomotive-designelectric-powertrainsustainable-materialsFirst 3D X-ray views of magnesium could transform car manufacturing
University of Michigan researchers have achieved the first-ever 3D X-ray imaging of microscopic structures inside magnesium alloys, revealing how these lightweight metals absorb mechanical stress without fracturing. Using advanced dark-field X-ray microscopy at the European Synchrotron Radiation Facility, the team visualized the formation and evolution of “deformation twins”—mirror-image crystal regions that increase magnesium’s ductility but can also lead to defects and cracks. Their experiments showed that all three types of twins form at triple junctions where three crystals meet, with defects consistently appearing where twins contact other crystals. This insight into magnesium’s stress response is crucial for optimizing its durability in automotive applications. Magnesium alloys, being 30% lighter than aluminum, hold promise for making cars stronger, lighter, and more fuel-efficient, but their broader use has been limited by unpredictable behavior under strain. The study, funded by the U.S. Department of Energy and published in Science, provides a detailed understanding of magnesium’s crystalline slip systems and twinning mechanisms
materials-sciencemagnesium-alloyslightweight-materialsautomotive-materialsX-ray-microscopydeformation-twinsenergy-efficient-vehiclesNew study by US engineers improves strength prediction in 3D printing
A research team at the University of Maine, led by engineers Philip Bean, Senthil Vel, and Roberto Lopez-Anido, has developed a novel method to improve strength prediction in lightweight 3D-printed parts, focusing on the gyroid infill pattern. This pattern, commonly used in additive manufacturing to reduce weight while maintaining strength, was analyzed through a combination of advanced computer modeling and physical stress testing. The team validated their finite element analysis (FEA) simulations with real-world compression and shear experiments, resulting in semi-empirical equations that enable more convenient and accurate strength predictions for design and optimization purposes. This approach addresses limitations of traditional analytical methods that struggle with complex internal geometries, providing deeper insights into how gyroid infill distributes stress and contributes to overall structural performance. The improved predictive capability allows engineers to optimize designs by balancing material efficiency and structural integrity, reducing material usage without compromising strength. The breakthrough is expected to benefit industries requiring strong, lightweight components, such as aerospace, automotive, and
3D-printingadditive-manufacturingmaterials-sciencegyroid-infillstructural-strengthlightweight-materialsmechanical-engineeringInside The Slate Auto Factory - CleanTechnica
Slate Auto, partially backed by Jeff Bezos, is positioning itself as an "anti-Tesla" in the electric vehicle market by focusing on simplicity and utility rather than high-tech features. Unlike Tesla’s feature-rich electric cars, Slate builds bare-bones electric trucks designed to be tough, practical, and affordable. The base model comes with unpainted, dent- and rust-proof gray polypropylene panels and weighs about 3,600 pounds with a standard 52.7 kWh battery, significantly lighter and smaller than Tesla’s Cybertruck. Customers can customize their trucks with optional upgrades, including kits to convert the vehicle into a five-seat fastback or a squared-off style reminiscent of classic rugged trucks like the Ford Courier or Jeep Wrangler. The starting price is estimated around $25,000, emphasizing affordability and straightforward utility. Slate’s manufacturing approach centers on simplifying production to reduce costs and accelerate market entry. The company is currently hand-building prototypes and pre-production vehicles at a small assembly line in Orion Township, Michigan, while its main production facility is being established in a former printing plant in Warsaw, Indiana, with a planned capacity of up to 150,000 vehicles per year. Slate’s leadership emphasizes flexibility in their production plans and aims to deliver a new category of electric trucks that meet essential needs without unnecessary complexity. This strategy is intended to disrupt the market by providing honest, no-frills electric trucks at a lower price point, contrasting sharply with the more luxurious and heavier electric trucks currently dominating the market.
energyelectric-vehiclesbattery-technologyautomotive-manufacturinglightweight-materialselectric-trucksclean-energy