A 30 minute documentary by ABC’s Quantum (1986)
Some very interesting historical facts I wasn’t aware of….
(check link for video)

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The Holden story (part 1): that’s our car!

Did you know that the Holden was not the first car to be designed and built in Australia?

In this video from the ABC Science vault, Justin Murphy retraces the history of the Australian car industry from that original Australian-made car, the 1901 Tarrant, through war, depression and war again — all events that led to the manufacture of the first Holden.

It’s a tale of challenges and triumphs as well as missed opportunities, and contains extensive and rare interviews with Sir Laurence Hartnett, the man who did more than anyone to create the local industry.

From the outset, local manufacturers had to compete with imported cars. And to do that, they had to become experts at low volume production.

The other issue, even in 1948, was one that would prove pivotal to the long term future of the industry — the question of ownership and control.

This program was first broadcast in 1986 by the ABC’s Quantum program, shortly after Sir Laurence passed away. It remains the definitive account of how the Australian car industry came to be.

http://www.abc.net.au/science/articles/2014/11/24/4114155.htm

maybe 3d printed cars will do away with the importing of cars?

wookiemeister said:

maybe 3d printed cars will do away with the importing of cars?

That’s fine for small volume manufacture. My former CSIRO Division is now 3D printing parts in titanium.

I like the idea of cars made completely of carbon fibre composite. Lay down a sheet of composite and stamp it into a 3D shape using a lightweight mould. Two panels per second ought to be possible. Then glue the car chassis together, no need for bolts or welds, not high price, if a part fails pull it out and replace it.

mollwollfumble said:

wookiemeister said:

maybe 3d printed cars will do away with the importing of cars?

That’s fine for small volume manufacture. My former CSIRO Division is now 3D printing parts in titanium.

I like the idea of cars made completely of carbon fibre composite. Lay down a sheet of composite and stamp it into a 3D shape using a lightweight mould. Two panels per second ought to be possible. Then glue the car chassis together, no need for bolts or welds, not high price, if a part fails pull it out and replace it.

Crazy idea

You make a 3d printer shape then vacuum mould the sheet over the 3D printer shape

The plastic is thermosetting plastic and cures after it is vacuum shaped over the mould

mollwollfumble said:

I like the idea of cars made completely of carbon fibre composite. Lay down a sheet of composite and stamp it into a 3D shape using a lightweight mould. Two panels per second ought to be possible. Then glue the car chassis together, no need for bolts or welds, not high price, if a part fails pull it out and replace it.

Cars have been made from carbon fibre in motorsport for 30 years now.
However they can’t be made the way you describe, the carbon mat has to be hand-laid into the mould then vacuum-bagged, then put into a large autoclave for something like eight hours to cure.
For sure the laying process could be automated but to do it properly you still have to vacuum bag and then autoclave the part so it gets full strength. Without doing that the carbon part is usually not much lighter (holds too much excess resin) and not much stronger than a good equivalent fibreglass part.
That being said, there are now 3D carbon filament printers starting to come onto the market. Since they use a different process to create the part, the part may well end up (say) about 80% as good as a traditionally made carbon part.
I am a big fan of carbon tubs for even road cars, as it reduces the overall mass of the car by quite a lot, increases the stiffness of the chassis also by quite a lot, and if properly designed will have better crash resistance.

What components of a car could definitely NOT be made from carbon fibre?

dv said:

What components of a car could definitely NOT be made from carbon fibre?

Windscreen

Spiny Norman said:

mollwollfumble said:

I like the idea of cars made completely of carbon fibre composite. Lay down a sheet of composite and stamp it into a 3D shape using a lightweight mould. Two panels per second ought to be possible. Then glue the car chassis together, no need for bolts or welds, not high price, if a part fails pull it out and replace it.

Cars have been made from carbon fibre in motorsport for 30 years now.
However they can’t be made the way you describe, the carbon mat has to be hand-laid into the mould then vacuum-bagged, then put into a large autoclave for something like eight hours to cure.
For sure the laying process could be automated but to do it properly you still have to vacuum bag and then autoclave the part so it gets full strength. Without doing that the carbon part is usually not much lighter (holds too much excess resin) and not much stronger than a good equivalent fibreglass part.
That being said, there are now 3D carbon filament printers starting to come onto the market. Since they use a different process to create the part, the part may well end up (say) about 80% as good as a traditionally made carbon part.
I am a big fan of carbon tubs for even road cars, as it reduces the overall mass of the car by quite a lot, increases the stiffness of the chassis also by quite a lot, and if properly designed will have better crash resistance.

My brother race/cruises on a 51foot carbon fibre yacht. It’s a common yacht construction material.

Dropbear said:

dv said:

What components of a car could definitely NOT be made from carbon fibre?

Windscreen

It could if you fitted a TV screen to the inside.

Tamb said:

Dropbear said:

dv said:

What components of a car could definitely NOT be made from carbon fibre?

Windscreen

It could if you fitted a TV screen to the inside.

Ok then TV screen

Come to think of it probably carbon fibre tyres wouldn’t be great

Dropbear said:

Tamb said:

Dropbear said:

Windscreen

It could if you fitted a TV screen to the inside.

Ok then TV screen

Ha, touché.

Dropbear said:

Tamb said:

Dropbear said:

Windscreen

It could if you fitted a TV screen to the inside.

Ok then TV screen

I’ll give you that one. :)

dv said:

What components of a car could definitely NOT be made from carbon fibre?

Quite a lot, but there could still be equally quite a lot more built from carbon fibre as well.
It’s just very expensive to do.

All the engine internals couldn’t (though do a search for Polimotor, it’s interesting. Also ceramic engines) drivetrain internals couldn’t (though the casings could be, as they sometimes are in Formula One cars). For a RWD car the tailshaft can and sometime is made from carbon, though again very expensive.