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Articles by Stewart Mitchell
Robotic Dry Fiber Cell and 2,400-Ton Composite Press Reduce Aerostructure Build Time by 90%
The integrated COMPASS cell runs as one entity. Dry fiber cutting and preforming feed directly to the Langzauner composite press via FANUC robots traversing a shared 85 meters of track.
Whitmer's Data Center Push Isn't Just Bad for Michigan - It's Bad for the World
"We're used to people saying 'fuck no' and doing it anyway." These words were seemingly spoken by our very own Governor Gretchen Whitmer earlier this month, caught on a hot mic chatting with Oracle executive Clay Magouryk. The two were celebrating breaking ground on the controversial new AI data center in rural Saline, Michigan - currently the largest data center project in the country. Governor Whitmer is apparently happy to sell Michigan out to military tech giants OpenAI and Oracle.
Whitmer’s Data Center Push Isn’t Just Bad for Michigan – It’s Bad for the World
“We’re used to people saying ‘fuck no’ and doing it anyway.” These words were seemingly spoken by our very own Governor Gretchen Whitmer earlier this month, caught on a hot mic chatting with Oracle executive Clay Magouryk. The two were celebrating breaking ground on the controversial new AI data center in rural Saline, Michigan — currently the largest data center project in the country. Governor Whitmer is apparently happy to sell Michigan out to military tech giants OpenAI and Oracle.
Whitmer’s data center push isn’t just bad for Michigan—it’s bad for the world
“We’re used to people saying ‘fuck no’ and doing it anyway.” These words were seemingly spoken by our very own Governor Gretchen Whitmer earlier this month, caught on a hot mic chatting with Oracle executive Clay Magouryk. The two were celebrating breaking ground on the controversial new AI data center in rural Saline, Michigan—currently the largest data center project in the country. Governor Whitmer is apparently happy to sell Michigan out to military tech giants OpenAI and Oracle.
Whitmer’s Data Center Push Isn’t Just Bad for Michigan - It’s Bad for the World
by Jackie Barlow and Stewart Mitchell, CODEPINK Detroit [Image credit: Jim West/UCG/Universal Images Group via Getty Images] “We’re used to people saying ‘fuck no’ and doing it anyway.” These words were seemingly spoken by our very own Governor Gretchen Whitmer earlier this month, caught on a hot mic chatting with Oracle executive Clay Magouryk.
Single endless roving placement saves up to 70% CFRP weight, enables closed-loop fiber recovery
The Holy Technologies IFP end effector winds a continuous carbon fiber tow around perimeter metal pins that hold each pass under tension and define the net-shape preform boundary during robotic layup. Source (All Images) | Holy Technologies Global carbon fiber-reinforced polymer (CFRP) demand has grown at around 12% annually since 2010; by 2050, projected waste volumes are expected to reach 500,000 tonnes.
Braided CF/LMPAEK tube system reduces liquid hydrogen fuel line weight by 50-60%
Co-consolidated integral CF/LMPAEK flanges form a continuous thermoplastic material system with the tube body, eliminating the metallic hardware and adhesive interfaces that conventional cryogenic line assemblies require. Source (All Images) | herone GmbH Hydrogen (H2) gas liquefies at a temperature of -253°C (20.28 K) under atmospheric pressure, just 20 degrees above absolute zero.
Industrial ultrasonic NDT adaptation permits accessible composite bicycle inspection
Ultrasonic probe on composite frame surface searches for damage. Source (All Images) | Cycle Inspect The hidden nature of composite damage poses an unusual challenge for the cycling industry. “A CFRP frame can sustain significant internal damage in the form of delamination, matrix cracking or ply separation while displaying minimal or no surface evidence,” says Christopher Howson, Cycle Inspect (Newcastle, New South Wales, Australia) co-founder and NDT lead.
One-shot compression molding enables main rotor blades that achieve 20,000 hours between overhauls
Hill helicopter’s main rotor blade is a complex amalgamation of CFRP, GFRP, unidirectional and biaxial materials that is cured in a single process. Source (All Images) | Hill Helicopters Helicopter main rotor blades occupy an unusual position in the composite materials landscape. Unlike a wind turbine blade that rotates in relatively clean air, or an aircraft wing that experiences steady-state loading, a helicopter rotor blade operates in a persistently hostile aerodynamic environment.
Multilayer TPC achieves electrically conductive, gas-impermeable fuel cells at 100 microns
Carbon ID’s range of bipolar plate materials for hydrogen fuel cell applications. Source (All Images Excluding IDTexEx) | Carbon ID CW has written extensively about the growing use of hydrogen storage and fuel cells for a range of transport applications as countries committed to mitigate climate change. But with Trump’s emphasis on war and fossil fuels, the imperative for zero emissions has suffered some setback, and the drive for hydrogen has now pivoted to aviation.
Composite helicopter "monolage" modernizes private rotorcraft production
Hill Helicopter’s HX50 features a carbon fiber-reinforced polymer (CFRP) monolage construction with integrated lightning strike protection (LSP) and aerodynamic fairing. Source (All Images) | Hill Helicopters “The private helicopter industry has been stagnant for decades,” says Dr. Jason Hill, aeronautical engineer and founder of Hill Helicopters (Stafford, U.K.). “Brand new helicopters rely on very outdated technology, albeit with updates in avionics.
Electromagnetically transparent GFRP rotor for rare earth magnet-free electric motors
Demonstrator of the wireless power transfer system with hollow, electromagnetically transparent glass fiber-reinforced polymer (GFRP) rotor shaft. Source | Ludmilla Parsyak, Universität Stuttgart It’s not news that the automotive industry’s shift toward electrification is a huge technical challenge. However, the electrification itself represents just one part of a complex puzzle for the industry.
Ultrasonic welding for in-space manufacturing of CFRTP
Agile Ultrasonics has developed an advanced ultrasonic welding system that is integrated with a robotic arm. This innovation enhances precision and efficiency in welding applications. Source | Agile Ultrasonics In-space manufacturing (ISM), the concept of producing materials and components beyond Earth’s atmosphere, emerged in the 1970s, and has since advanced from theoretical research to practical experimentation.
Composites end markets: Automotive (2025)
Sources (top, clockwise) | Airel Motor Co., Röchling, Alia Mentis and Autoneum As the automotive sector confronts the pressing need to build low-emission or zero-emission vehicles in line with stringent global environmental mandates, the appetite for lightweight, sustainable materials and manufacturing processes in this industry has surged.
Hybrid composite architecture enables rigid wind propulsion solution for maritime decarbonization
The 20-meter AirWing installation aboard the Carisbrooke Shipping vessel maintains compatibility with cargo operations while delivering 8.3% fuel savings during the vessel's U.K.-Canada-U.K. route. Source (All Images) | GT Wings The global maritime industry is navigating a transformative period as regulatory pressure intensifies to reduce greenhouse gas emissions.
Oligomer polymer engineering transforms 100% recyclable thermoplastic composite paradigms
Wind turbine blades are being buried at their end of life (EOL), a practice soon to be prohibited by landfill bans taking effect across Europe in 2025. With a forecast of 43 million tons to be disposed by 2050, MET-OL's recyclable composite technology tackles this urgent sustainability problem. Source (All Images) | MET-OL The paradox of advanced composite materials has long frustrated sustainability efforts.
Thermoplastic composite pipes provide 59% reduction in H2 distribution CO2 emissions
Continuous thermoplastic composite pipe (TCP) manufactured in lengths up to 1.2 kilometers is wound onto 3-meter-diameter transportation spools, significantly reducing field joint requirements and enhancing installation efficiency compared to conventional steel solutions. Source (All Images) | Hive Composites As the global shift toward cleaner energy sources intensifies, hydrogen has emerged as a crucial element in decarbonization strategies.
Composite bipolar plates provide 81% improvement to hydrogen fuel cell power density
Hycco’s bipolar plate is showcased on a hydrogen fuel cell, where it plays a vital role in improving gravimetric performance. Source | Hycco Decarbonizing heavy mobility is a challenge that presents significant opportunities for hydrogen fuel cell powertrains. These systems offer the necessary power, range and durability essential for commercial applications, while reducing mass compared to battery electric options.
Pultruded CFRP chassis enables 36% payload increase for specialized commercial vehicles
CarbonTT’s carbon fiber-reinforced polymer (CFRP) chassis is integrated into the Borco Höhns Fiat Ducato. The advanced composite design reduces the chassis weight by 185 kilograms, enhancing payload capacity and operational efficiency. Source | Borco Höhns In the evolving landscape of urban logistics and mobile commerce, the demand for specialized, lightweight commercial vehicles has surged.
Carbon fiber/flax landing gear achieves 54% weight reduction via tailored layup optimization
Biogear landing gear demonstrates a hybrid composite structure with visible carbon fiber/flax sections (black) and metallic interface components (silver). Source (All Images) | Fuko Substituting metallic structures with composite materials presents a promising strategy for reducing the weight of aerospace components.
All-recycled, needle-punched nonwoven CFRP slashes carbon footprint of Formula 2 seat
Dallara’s Formula 2 (F2) seat made from 100% recycled needle-punched nonwoven carbon fiber. Source | Dallara Formula Two (F2) is the Fédération Internationale de l’Automobile’s (FIA) second-tier single-seater global racing championship — just under Formula One (F1), the top-tier. F2 serves as the final stage of the FIA Global Pathway from Karting to F1. It's a spec series, meaning drivers compete in identical machinery to showcase true talent.
Bladder-assisted compression molding derivative produces complex, autoclave-quality automotive parts
The carbon fiber composite roof of the Maserati MC20 is achieved using HP Composites’ AirPower technology, a derivative of bladder-assisted compression molding (BACM). Source |Maserati In the realm of high-performance automotive manufacturing, carbon fiber-reinforced plastic (CFRP) components have become increasingly crucial for achieving optimal strength-to-weight ratios and complying with stringent efficiency requirements.
Ultra-thin woven fabric enables 90% resource reduction in satellite solar array manufacturing
A constellation of satellites is prepped for deployment, housed within a rocket's payload bay. These satellites are equipped with rapidly manufactured composite deployable solar arrays. Source | Kerberos Engineering In recent years, there has been a notable increase in the global demand for composites tailored for space applications, driven by the emergence of private space firms and satellite manufacturing in the race to increase accessibility to space.
Laser-excited acoustics provide contact-free, nondestructive composites inspection
Xarion’s laser-excited acoustics (LEA) is a couplant-free nondestructive testing (NDT) method that uses laser principles and an optical microphone without a membrane. In a single-sided “pitch-catch” configuration to test a sandwich panel, the LEA system demonstrates the precision of the laser and optical microphone in identifying structural irregularities.
Annual Reserving Seminar - What does a good reserving process look like in 2024 and beyond?
We are delighted to invite you to watch our annual reserving seminar. We will discuss: Reserve deteriorations: Where has it gone wrong, what could have been avoided and what are the risks for the future? Reserving transformation: how to minimise pain and maximise value. How you can unlock value from the reserving process and turn it into a source of competitive strength. Please also share this invite with any colleagues who may be interested.
Aviation-specific battery system uses advanced composites to address electric, hybrid flight
BOLDair is a specialized solution that addresses the distinct energy storage needs of electric and hybrid propulsion systems used in aircraft. It boasts a body that is constructed entirely out of composite materials, resulting in a weight of only 52 kilograms. As a result, it is considered one of the most high-performing batteries on the market in terms of gravimetric performance.
Automated robotic NDT enhances capabilities for composites
The Accubot is an advanced nondestructive testing (NDT) technology that leverages the latest developments in robotics, intelligent software and process optimization to offer high measurement freedom for composite structures. Photo Credit: Fill Highly engineered materials like carbon fiber-reinforced polymer (CFRP) composites are preferred in aerospace applications for their exceptional strength-to-weight ratio, thermal stability and durability.
The Meaning Behind The Song: Time Passing By by Stewart Mitchell
The Meaning Behind The Song: Time Passing By by Stewart Mitchell Time Passing By, a hauntingly beautiful song written by Stewart Mitchell, takes listeners on a journey through the depths of emotions and memories. This melodic masterpiece is a poignant reminder of the transient nature of life and the bittersweet moments that fade away with the passage of time.
Exciting Results from the Solway Yacht Club Autumn Open Spectacular in Kippford
Key points: The Solway Yacht Club Autumn Open Spectacular took place in Kippford, with participants from various locations. The event included races in the Finns, International OKs, ILCAs (Lasers), and National 12s classes. John Mackie, Ivan Burden, and David Kitchen were among the winners in their respective classes. The Solway Yacht Club recently hosted their Autumn Open Spectacular, inviting several leading racing dinghy classes to participate.
Solway Yacht Club Autumn Open Spectacular
Solway Yacht Club Autumn Open Spectacular by Ian Purkis and Stewart Mitchell 3 Oct 04:51 PDT Several leading racing dinghy classes were invited to Kippford for the Club's big late season Open leading to a strong entry including Finns, International OKs, ILCAs (Lasers) and National 12s. Crews had arrived from the Highlands to the English South Coast and everywhere in between.
Modular, robotic cells enable high-rate RTM using any material format
Airborne’s automated ply placement (APP) technology represents the culmination of advancements in robotics, intelligent software and process optimization. It is a robotically operated, automated and modular preforming solution that maximizes composite component design and material freedom prior to resin transfer molding (RTM) processing. Photo Credit: Airborne The use of composite materials in vehicle and aircraft manufacturing is proliferating.
Enhancing Vehicle Safety with Technology: How the Latest Euro NCAP Results Mark a Shift Towards New Sensing Technologies
Euro NCAP Changes for 2023 The European New Car Assessment Programme (Euro NCAP), which assesses the safety performance of new vehicles entering the European market, is the benchmark for vehicle safety. The testing and performance protocols used in the Euro NCAP are regularly updated to reflect technological advancements in vehicles to ensure they represent the latest and highest safety standards.
Hybrid process marries continuous, discontinuous composites design
9T Labs has developed a hybrid manufacturing technique using its Additive Fusion Technology (AFT), positioning continuous fiber preforms in high-stress regions of a part and discontinuous fiber where there is less reliance on continuous fiber’s strength characteristics. Photo Credit, all images: 9T Labs Carbon fiber-reinforced thermoplastics (CFRTP) offer an exceptional strength-to-weight ratio, which makes them attractive for structural applications in many industries.
Thatcham Research Guidance Enables Sustainable Headlamp Repair.
The automotive industry has witnessed a remarkable transformation in headlamp technology in recent years. Traditional halogen bulbs have given way to state-of-the-art coded components integral to operating various Advanced Driver Assistance Systems (ADAS) and assisted driving functions that improve safety. However, headlamps are one of the most damage-vulnerable components on a vehicle.
GKN Aerospace opens new Netherlands-based Global Technology Center
Photo Credit: GKN Aerospace On May 8, GKN Aerospace (Redditch, U.K.) opened a Global Technology Center (GTC) in Hoogeveen, the Netherlands, to provide an innovation ecosystem for composites research and accelerate the development of the latest sustainable aviation technologies in the region as part of an €80 million investment package from GKN Aerospace. The center focuses on lightweight thermoplastic composites and advanced electrical cabling systems for next-generation aircraft.
Composites-reinforced concrete for sustainable data center construction
Metromont's C-GRID-reinforced insulated precast concrete's high strength, durability, light weight and ease of installation improve data center performance, construction time and sustainability. "Internet connectivity drives today's world, affecting life at all scales. All online activity generates data, and even though the data itself is transmitted and received wirelessly, physical hardware is what makes it possible.
Racecar Engineering June 2023 Issue Out Now
Stewart is a degreed engineer, professional technical researcher and engineering journalist with proven experience in producing some of the most comprehensive technical content ever published on some of the most high-profile motorsport technology ever made. He brings his knowledge and experience to Racecar Engineering to enable readers to explore a diverse range of contemporary motorsport technology and engineering phenomena in a plethora of racing disciplines.
Formula 1 Digital Magazine April 2023
2023 marks the 2nd year of Formula 1’s ground effect regulations and a new regime for many teams, taking the learnings from the first year. Racecar Engineering brings you up to date with an in-depth look at some of Formula 1’s top technology stories, insights into classic racers, and the 2026 PU regulations in this new digital magazine. Check it out below!
Forze IX Hydrogen Racing Fuel Cell Racer
Hydrogen is an abundant element when it comes to fuelling propulsion. Its potential to replace liquid fuels in internal combustion engines is an exciting prospect for many car makers, and the drivers for its implementation in that regime are vast. However, there is another significant opportunity for hydrogen in vehicle propulsion in the form of hydrogen fuel cell electric power.
Red Bull Powertrains Adopts ADTs TURBOdesign Suite
Advanced Design Technology (ADT), a turbomachinery design and optimisation company, will partner with Red Bull Ford Powertrains with its selected TURBOdesign Suite software for their design and optimisation of the 2026 Power Unit turbocharger. TURBOdesign Suite is a turbomachinery design software package based on 3D Inverse Design technology. It helps engineers significantly cut design time and cost to create breakthrough designs for high-performance fans, pumps, compressors and turbines.
Composites-reinforced concrete for sustainable data center construction
Peak 10’s 60,166-square-foot purpose-built, multistory data center facility in North Tampa, Fla., U.S., was fabricated using Metromont’s C-GRID-reinforced insulated precast concrete panels for high efficiency operation. Photo Credit: Metromont Internet connectivity drives today’s world, affecting life at all scales. All online activity generates data, and even though the data itself is transmitted and received wirelessly, physical hardware is what makes it possible.
Racecar Engineering May 2023 Issue Out Now
Racecar Engineering May issue: F1 2023 Round-Up ByKolles-built LMH Racer 1936 Mercedes W25K F1 car Simulation In IndyCar F1 Hybrid Power Unit Management Forze IX Hydrogen Fuel Cell Racer Much More!
Red Bull Powertrains RBPTH001
Top Secret Kakuda would not be drawn to expose the details of the changes, calling them ‘top secret’. However, he admits that ‘we explored many different paths in developing this area and tried many different configurations. We have also developed very accurate simulations to prove our concepts before implementing them into a mechanical system.’ The RBPTH001 takes advantage of a significant amount of additive-manufactured (AM) parts.
Aston Martin F1 Explains How It Built the AMR23
The construction of the Formula 1 car is a complex technical and logistical challenge that involves hundreds or, in some cases, thousands of personnel.
BosonQ Psi | Harnessing the Disruptive Power of Quantum Computing
Quantum computing could enable efficient simulation for racecar innovation by overcoming the computational bottleneck. Unlike the traditional computer, established on bits and bytes, quantum computing (QC) uses super-positioning and entanglement – theoretical concepts of quantum mechanics – to process information. This property allows quantum computers to perform calculations that are impractical, or even impossible, for classical computers.
Hypercar Explained
The Hypercar category, a joint project of the FIA and the ACO, that back in 2018 was envisaged as the new top class of the FIA World Endurance Championship, had its debut in 2021, but it wasn’t until this year when this ruleset really came of age, attracting a raft of manufacturers.
Ferrari 499P LMH
Ferrari has long been present in endurance racing, but over 50 years since it last won at Le Mans. The brand has been represented successfully in GT racing by the Squadra Corse arm of the company for over 20 years, in partnership with Amato Ferrari’s AF Corse team. That relationship will continue with the new Ferrari 499P Prototype. World Championship titles have gone the way of the Scuderia in GT racing.
IndyCar Aeroscreen
Fighter jet pilots and NTT IndyCar racecar drivers have more in common than simply the need for speed. PPG impact-resistant transparencies protect both from being struck by flying objects. Designed by Red Bull Advanced Technologies, the Aeroscreen consists of a PPG laminated polycarbonate windscreen attached to a titanium frame produced by Pankl of Austria, all intended to reduce the risk of driver injury from flying debris.
Tyre Warmers Scrapped for WEC
One of the biggest changes to the World Endurance Championship (WEC) regulations for 2023 is the loss of tyre warmers in all classes in the WEC. The governing bodies, Automobile Club de l’Ouest and the FIA, announced that tyre warmers would be scrapped from both the WEC and European Le Mans Series this year in a move “designed to reduce the teams’ environmental impact”.
F1 2023 Performance Insights
As the 2023 F1 season gets underway, Racecar Engineering presents its performance insights in this, the second year of F1’s new era. So far in 2023, the ten teams have introduced a whirlwind of new designs derived from a whole host of learnings taken from the first season of these new regulations in 2022.
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