Chevrolet’s 3-D prototype process may drive the development of cooler cars in the future

A new process used to update the Chevrolet Malibu for the 2014 model sounds more like the plot of a sci-fi movie than anything tied to designing cars.  

    

To refresh the Malibu’s interior and exterior, Chevrolet designers used a process known as rapid 

prototyping, which involves 3-D printing of parts.

The technology, as described in a Chevrolet press release, “literally” grows prototype parts out of powder or liquid resin at a fraction of the cost associated with building tools to make test parts.

Rapid prototyping, which uses processes officially known as selective laser sintering and stereo lithography, requires specialized software, math data and digital lasers, which accomplish in days what would have taken weeks of clay sculpting in the past, notes Chevrolet.

In a nutshell, it enables designers and engineers to more quickly build test versions of car components and systems that they can actually see, touch and feel in precise one-third scale and full-size models without having to make changes to production tooling, saving hundreds of thousands of dollars.

“When you need to get intricate, fully functional prototype parts quickly, nothing beats rapid prototyping,” said Todd Pawlik, chief engineer, Chevrolet mid- and full-size cars. “Our ability to rapidly fabricate inexpensive prototype parts throughout a vehicle enables key components to get confirmed earlier so that we can go from computer models to production-caliber parts.”

  

On the Malibu, rapid prototyping was used to update the sedan’s new floor console (below), which now features a pair of integrated smartphone holders for the driver and passenger. The new console also weighs less, which helps contribute to the Malibu’s improved fuel economy over the previous model.

2015 Chevy Vehicles with Built In Wi-Fi

GM announced that for the 2015 line-up of Chevrolet pick-ups will have 4G LTE, Wi-Fi built in. The GM teamed up with AT&T to embed the mobile broadband modems in the vehicles. Owners of new 2015 Chevy pick-ups will get much faster data speeds for safety and convenience features as well as a more future-proof infotainment system.

What does this all mean exactly? Well, 4G capability will bring enhanced features and services into the car, including creating an in-vehicle Wi-Fi hotspot, which allows streaming video for back-seat passengers, encourage faster development of in-dash applications and foster over-the-air software updates. It will also provide faster response for the safety features and services of OnStar telematics system.

The automaker said that these “enhancements build on OnStar’s existing portfolio of built-in connected services." Verizon has been the carrier since 1996 when OnStar was first introduced, that will no longer be come 2014. There aren’t any details yet on what kind of monthly costs drivers who opt for this LTE connection will incur, but GM does mention that it will integrate with OnStar so the option might be an added tier to that service.

This is something we are definitely excited about. AT&T's 4G connectivity could also make GM’s infotainment systems more future-proof. "So when the next great streaming music service comes out in two years,” Greg Ross, director of business development and strategic alliances for GM’s Global Connected Consumer division, “you’ll be able to add that to the car and we can make it available at any time.”