What do rockets, ski boots and submarines have in common? They can all be assembled with plastic-printed components.

Most rapid prototyping service providers specialize in one area of additive manufacturing, such as fused deposition modeling (FDM) or metal sintering. ZARE SrL, however, offers expertise in several areas.

DEARBORN, MI—Ford Motor Co. is developing new foam and plastic components using carbon dioxide as feedstock. Researchers expect to see the new biomaterials in production vehicles within five years.

DEARBORN, MI—Ford Motor Co. is formulating and testing new foam and plastic components that uses carbon dioxide as feedstock. Formulated with up to 50 percent CO₂-based polyols, the new materials could reduce petroleum use by more than 600 million pounds annually.

WARREN, MI—General Motors engineers have developed a technique to join steel to aluminum with resistance spot welding.

Back in the day, engines were the exclusive domain of cast iron and steel. But, during the past decade, more lightweight materials, such as aluminum and hard thermoplastics, have been slowly creeping under the hood. The Holy Grail, an engine made almost entirely out of plastic, is finally close to reality.

When it comes to developing new production tools and assembly processes, it’s hard to beat Boeing. The company has always been ahead of the curve implementing new technology on its assembly lines.

DETROIT—General Motors is turning its employees’ recycled water bottles into noise-reducing fabric insulation that covers the engine in the Chevrolet Equinox. The bottles—collected from five of its Michigan facilities—are also being turned into air filtration components and insulation for winter coats for the homeless.

Friction stir spot welding has many advantages compared with riveting or resistance spot welding.

As plastic medical devices get smaller and more intricate, engineers have fewer options for assembling them.