Articles tagged with "manufacturing-innovation"
US lab makes graphite from coal waste, can be used in nuclear reactor
The US National Energy Technology Laboratory (NETL) has developed a novel low-temperature catalytic process to produce high-quality graphite from coal waste and other carbon-rich materials such as coal char, bio-char, petroleum coke, and plastic waste. This innovative method uses earth-abundant catalysts like iron to facilitate the formation of highly crystalline graphite at temperatures below 1,500 degrees Celsius, significantly lower than the conventional 3,000 degrees Celsius. The process is also faster, reducing production time from weeks to hours, and the catalyst can be recycled indefinitely, improving economic viability. Graphite produced through this method performs comparably to commercial graphite in applications such as lithium-ion battery anodes. Graphite is classified as a critical mineral in the United States due to its essential role in manufacturing, including battery electrodes, steel production, and nuclear power, combined with supply chain vulnerabilities. Currently, the global graphite market is heavily dominated by China, which produces about 70% of natural graphite and 60% of synthetic graphite.
materialsgraphitecoal-wastebattery-technologyenergy-storagecritical-mineralsmanufacturing-innovationReinvented 300-year-old cello earns US student Shark Tank deal
Elijah Lee, a biomedical engineering senior at Yale and co-founder of Forte3D, has reinvented the traditional cello by using 3D printing combined with carbon fiber and polymer composites. Originating from a high school project, Lee aimed to create a cello that is more affordable, durable, and portable than conventional wooden instruments, which often cost over $5,000 and are fragile. The innovative cello features flat carbon-fiber panels for the top and back, 3D-printed ribs and neck, and retains traditional parts like the sound post and fingerboard to preserve authentic sound quality. Utilizing rapid Computer-Aided Design (CAD), the team can precisely adjust the instrument’s shape and materials to optimize acoustics, surpassing the limitations of carved wood. After six years and hundreds of prototypes, Forte3D’s cello has attracted attention from renowned musicians such as Yo-Yo Ma and The Piano Guys. The company also offers customizable finishes to reflect individual player styles. Forte3D secured a $
3D-printingcarbon-fiberpolymer-compositesmaterials-engineeringmusical-instrumentsadvanced-materialsmanufacturing-innovationTesla to begin Cybercab production in April, Musk claims
Tesla CEO Elon Musk announced that production of the Cybercab, a fully autonomous electric robotaxi without pedals, steering wheel, or side mirrors, will begin in April at Tesla’s Austin, Texas factory. The vehicle is designed specifically for unsupervised full self-driving and optimized for the lowest cost-per-mile in autonomous mode. Musk claimed the manufacturing process will be highly efficient, with a 10-second cycle time per vehicle, potentially enabling production of two to three million Cybercabs annually. This announcement followed a shareholder meeting where Musk was awarded a historic compensation package potentially worth $1 trillion in company shares. Despite Musk’s bold claims, Tesla has yet to demonstrate fully driverless operation at scale without a safety monitor, and his statements conflict with Tesla chairwoman Robyn Denholm’s recent remarks that the Cybercab would include steering controls as a backup. Tesla had initially planned versions with traditional controls but shifted to stripped-down models. Regulatory approval remains a significant hurdle, as vehicles lacking standard controls require federal exemptions to
robotautonomous-vehiclesTesla-Cybercabself-driving-carsrobotaxielectric-vehiclesmanufacturing-innovationTesla's Unboxed Manufacturing Process — How It Works & Why - CleanTechnica
Tesla has been granted two new US patents for its innovative "unboxed manufacturing process," which promises to revolutionize automobile production by enabling faster assembly with fewer workers, lower costs, and smaller factory footprints. Unlike traditional auto manufacturing—where a vehicle’s body is assembled as a single "box" into which all systems are later installed—the unboxed process involves completing major sub-assemblies, such as the dashboard or front end, separately before joining them. This modular approach allows different components to be built in parallel rather than sequentially on a single assembly line, reducing bottlenecks and increasing efficiency. A key advantage of the unboxed method is its potential to halve production costs and factory size while dramatically speeding up manufacturing. The process also addresses common pain points like corrosion resistance and painting: instead of treating and painting the entire body as one unit with attached doors and panels, these parts are treated and painted separately and then fitted to the body. This reduces complexity and streamlines interior installation. Overall, Tesla’s
roboticsmanufacturing-innovationTeslaautomotive-manufacturingautomationindustrial-robotsproduction-efficiencyMade in space: Varda’s William Bruey shares plan to build the next great supply chain at TechCrunch Disrupt 2025
William Bruey, founder and CEO of Varda Space Industries and former SpaceX engineer, will present at TechCrunch Disrupt 2025 about pioneering manufacturing in orbit. His company is developing space-based factories that leverage microgravity to produce high-value materials—such as advanced pharmaceuticals and superior fiber optic cables—that cannot be made on Earth. Varda’s approach involves manufacturing these breakthrough products in orbit and then safely returning them to Earth, positioning space as a new and potentially highly profitable industrial frontier. Bruey’s session at the event, held October 27–29, 2025, in San Francisco, highlights the intersection of space innovation and startup culture, showcasing how physics and venture capital combine to create the next industrial revolution beyond Earth. With a background in applied physics, systems engineering, and experience flying multiple SpaceX missions to the ISS, Bruey brings deep technical expertise and entrepreneurial vision to this emerging space economy. TechCrunch Disrupt 2025 will feature over 200 sessions and
space-manufacturingadvanced-materialsmicrogravity-productionspace-industrymanufacturing-innovationfiber-optic-materialspharmaceuticals-manufacturingNew tech 3D-prints durable zirconia dental crowns in just hours
Researchers at the University of Texas at Dallas have developed a groundbreaking 3D-printing technology that enables the production of permanent zirconia dental crowns in just a few hours, potentially allowing patients to receive same-day restorations. Zirconia is considered the gold standard for durable dental work, but traditional manufacturing methods, such as milling, limit design complexity and risk micro-cracking. Existing 3D-printed crowns use ceramic resins that lack zirconia’s strength. The key innovation lies in drastically reducing the debinding process—from 20-100 hours to under 30 minutes—by using porous graphite felt, enhanced heat transfer, and a vacuum system that safely removes gas during resin burnout, preventing cracks and fractures. This advancement not only accelerates the production timeline but also offers stronger, more customizable dental restorations compared to resin alternatives and milled zirconia. The technology promises to lower waste and costs while improving patient experience by enabling dentists to provide permanent crowns, bridges, and veneers chair-side in a
materials3D-printingzirconiadental-technologymanufacturing-innovationrapid-prototypingdental-restorationsArgonne Lab's EV battery breakthrough to cut energy use by half
Researchers at the US Department of Energy’s Argonne National Laboratory, in collaboration with Oak Ridge National Laboratory and Case Western Reserve University, have reviewed advanced battery electrode manufacturing techniques that could cut energy use by more than half and reduce factory footprints. The study highlights dry processing as the most promising near-term technology, as it eliminates the need for the solvent N-methyl-2-pyrrolidone (NMP) used in conventional wet electrode processing. Wet processing involves mixing active materials with solvents to form a slurry that is coated and dried in energy-intensive ovens, with additional costs and complexity from safely recovering NMP. Dry processing compresses mixed powders directly into electrode films, potentially reducing manufacturing costs by 11% and energy use by 46%, though further research on binder stability is needed. Other emerging alternatives include advanced wet processing, which replaces NMP with water to cut energy costs by 25% but still requires drying ovens, and radiation curing, which rapidly solidifies slurries using light or electron
energybattery-technologyelectrode-manufacturingdry-processingsolvent-recoveryEV-batteriesmanufacturing-innovationFord throws out Henry Ford’s assembly line to make low-cost EVs in America
Ford announced a $2 billion investment to convert its Louisville Assembly Plant into a facility for producing a new generation of affordable electric vehicles (EVs), beginning with a mid-sized pickup truck priced around $30,000 and launching in 2027. This transformation involves abandoning the traditional moving assembly line system pioneered by Henry Ford over a century ago. Instead, Ford is implementing a novel "universal production system" that replaces the single conveyor line with a three-branched assembly tree, allowing separate assembly of the vehicle’s front, rear, and structural battery components before final integration. This approach aims to reduce manufacturing costs, speed up production by 15%, and use 20% fewer parts, enabling Ford to compete more effectively with Chinese EV manufacturers. The new EV platform will utilize large single-piece aluminum unicastings and lithium iron phosphate batteries licensed from China’s CATL, produced at Ford’s upcoming $3 billion BlueOval Battery Park in Michigan, expected to open in 2026. The development of
energyelectric-vehiclesbattery-technologymanufacturing-innovationlithium-iron-phosphateautomotive-industryFord-electric-trucksPrinting the future: Scott Miller on the power of hybrid electronics
The article features Dr. Scott Miller, Director of Technology at NextFlex, discussing the transformative potential of flexible hybrid electronics, which combine printed electronics with conventional semiconductor components. This integration allows electronic systems to be printed onto or embedded within objects, creating lightweight, adaptable devices with new form factors. These innovations are already impacting key industries such as defense, aerospace, and healthcare—for example, by printing antennas directly onto UAV airframes for improved robustness and reduced weight, and by enabling stick-to-skin wearable patient monitors that provide continuous health data and facilitate at-home care. Beyond performance benefits, hybrid electronics offer significant advantages for U.S. manufacturing and supply chains. By lowering capital costs, they empower small and mid-sized companies to compete without massive scale, promoting localized, distributed manufacturing that reduces environmental impact, shipping costs, and geopolitical risks. The printing process also minimizes material waste compared to traditional PCB fabrication. Additionally, hybrid electronics support a digital-first design-to-manufacturing workflow, accelerating prototyping and eliminating the need for
materialshybrid-electronicsprinted-electronicsflexible-electronicsmanufacturing-innovationaerospace-technologyhealthcare-devices