Manufacturing large, monolithic composite parts, such as a car body or an aircraft fuselage, requires a large and complex mold. As a result, the process can be quite costly. Alternatively, such complex parts can be manufactured less expensively by assembling a series of smaller parts using various joining techniques.

Traditionally, aircraft manufacturers have been reluctant to adopt robots and other types of automation. One of the main challenges is that large plane parts come with relatively high geometry deviations, so robots need sensor guidance.

Steel has been, is now, and will continue to be the predominant material for vehicle structures and body parts, such as doors, hoods, liftgates and fenders. But, other materials, such as aluminum, magnesium, plastics and composites, are becoming increasingly important.

Self-pierce riveting (SPR) is a cold joining process for fastening two or more sheets of material by driving a rivet through the top sheets and upsetting it, under the influence of a die, into the bottom sheet without breaking through it.

Drilling rivet holes in composite materials has been a challenge for many years. Traditionally, using standard tools has resulted in rapid tool wear and material damage, including integrity, surface quality and delamination.

Automotive and aerospace manufacturers have been at the forefront of the lightweighting trend for some time now. But, they're not the only ones. The railway industry could also benefit from the use of new, lightweight structural materials.

Countries around the world share a common goal of reducing carbon emissions. Finland, for example, aims to reduce its level of emissions by 5 percent (5 million kilograms) each year by investing in green technology for public transportation.

Aerospace engineers around the world have been searching for new ways to make aircraft lighter and more fuel efficient. Aeroelastic wings may be the answer.

Materials are important in every industry. But, they're critical to aerospace manufacturers. If companies select the wrong material for a particular application, it can have catastrophic consequences.

Strong and lightweight, carbon-fiber reinforced plastic (CFRP) offers numerous benefits to automotive and aerospace manufacturers. Many engineers are intrigued by potential applications for the material, yet remain frustrated by joining challenges.