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Overmould rib process for electric aircraft

The National Institute for Aviation Research (NIAR) at Wichita State University has developed a thermoplastic rib structure to simplify the manufacture of eVTOL systems, writes Nick Flaherty. The fully automated hybrid thermoforming and injection overmoulding process cuts production time from 100 hours to two minutes, marking a major breakthrough in aerospace manufacturing efficiency. By integrating two key polymer processing techniques, the process enables production of high-performance, lightweight components with greater design flexibility and cost efficiency.

Grid

AI for battery material discovery

SandboxAQ has developed a new approach to using artificial intelligence (AI) for the discovery of new battery materials, writes Nick Flaherty. The company has combined a chemical simulation platform with the transformer AI frameworks in large language models to create what it calls a ‘large quantitative model,’ or LQM.

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Electric ferry targets 2026

Incat in Australia is constructing a 78 m hybrid electric ferry that will be ready for operation in the first half of 2026, writes Nick Flaherty. The 78 m craft, as yet unnamed, has flexible propulsion options with a fully electric battery system of up to 12 MWh as well as hybrid and generator-assisted options. The system supports charging at rates up to 10 MW to reduce the turnaround time.

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Next generation SCiB module for heavy duty designs

Toshiba has developed a new version of its SCiB battery module for electric buses and ships, writes Nick Flaherty. The new version uses an aluminium baseplate that dissipates approximately twice the heat of current modules for higher power applications.

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Robot charging for Rotterdam

Rocsys has demonstrated its robot self-charging system working with electric trucks in a port in the Netherlands, writes Nick Flaherty. The Rocsys platform includes the first interoperable robotic hands-free charging system for ports, logistics and robotaxi industries. The demonstration was part of the European Magpie project to automate activity at ports and logistics centres.

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Battery pack designed for second life

A European project has developed a battery prototype designed for ease of assembly and disassembly of battery components, writes Nick Flaherty. The battery pack developed as part of the MARBEL project with car maker Stellantis uses a wireless battery management system (BMS), artificial intelligence (AI) and a digital twin capable of predicting a battery’s remaining useful life, as well as its state of charge and health.

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Digital twin for material optimisation

Henkel is launching digital twin modelling and simulation capabilities combined with real-world validation of structural materials used in e-mobility designs, writes Nick Flaherty. Henkel is combining its expertise in material application with in-house testing and validation to close the loop between digital and real-world design and testing.

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Busbar connector alternative to electroplating

Penn Engineering has developed a new technique to reduce the cost of busbar connections in electric vehicles, writes Nick Flaherty. “The challenge is how to connect busbars,” says John O’Brien, global technologist at Penn Engineering. “One of the things we have seen is a move from cabling to busbars, driven by cost. Busbars are much cheaper for the same current than cables and more suited for automated assembly, which also gives lower cost.”

Grid

Silicon nitrade ceramics help heat dissipation

The National Institute of Advanced Industrial Science and Technology (AIST) in Japan is working with NGK Insulators to standardise evaluation methods for measuring thermal diffusivity of thin substrates, writes Nick Flaherty.

Grid

Metal rupture discs offer robust relief

OsecoElfab has developed a family of pressure-relief systems for lithium ion battery applications for heavy-duty, offroad e-mobility applications, writes Nick Flaherty. The low-profile, specialised, metal rupture discs support custom battery design to improve safety. They provide robust emergency relief and pressure equalisation in a single device in the event of outgassing by the battery cells.