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  • Figure 2. A formed and machined extrusion for a body structure component, which has been designed to integrate well within the vehicle. (Source: UACJ Whitehall.)

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    Extrusions for Automotive – From the Voice of the Customer

    By Andrew Halonen, Mayflower Consulting LLC. Every business owner would like to have a better understanding of their customer to be sure they are meeting customer needs and are remaining competitive. So, how do they get this insight and feedback? The process is referred to as the voice of the customer (VOC). While this sounds […]

  • computer chips with AI printed on it

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    Growth Opportunities Using AI Tools in the Extrusion Market

    By Andrew Halonen, Mayflower Consulting LLC. How many aluminum industry executives have been asked by their employees, management team, or board what their artificial intelligence (AI) strategy is? While this is a fair question, if it has not yet been explored, it’s not easy to provide an answer. AI tools are being used today in […]

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    Machine Learning Brings Big Value to Light Metal Manufacturing

    By Andrew Halonen, Mayflower Consulting LLC. Material developers and producers are feeling global pressure to optimize their respective businesses, especially as communications get easier and as once-difficult tasks are optimized and commoditized by automation technologies. Gone are the days that a midwestern forging producer would automatically have a competitive advantage with an automotive OEM over […]

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    New Extrusion Applications in Commercial Vehicles

    By Andrew Halonen, Mayflower Consulting LLC. Commercial vehicles have one key difference from passenger cars. They are a tool to do work and are, therefore, specified and built with a certain application in mind, which is often referred to as the duty cycle. Maintenance of the commercial vehicle is necessary, yet downtime to fix the […]

  • Figure 1. Nissan Rogue.

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    Reducing the Cost of Aluminum Car Doors with Tailor-Welded Blanks

    By Andrew Halonen, Mayflower Consulting LLC. In automotive engineering, material selection is not a static activity. A decision made on today’s model could be reversed on the next one. This can be good or bad depending on one’s perspective. Materials manufacturers are continually innovating and bringing robust solutions to the market, providing vehicle OEMs with […]

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    The Potential for Magnesium Forgings in Automotive

    By Andrew Halonen, Mayflower Consulting LLC. In the world of product development, many materials are available to pick from, yet companies tend to play to their favorites. In metals, these materials range from exotic to common, from low density to high, and they are processed into different forms. The majority of car components — from […]

  • Rivian R1T electric pickup

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    The Value Proposition for Lightweighting in Electric Vehicles

    By Andrew Halonen, Mayflower Consulting LLC. Electric vehicles (EVs) and electrification of transportation in general are topics that dominate news outlets, magazines, and social media. OEMs, materials manufacturers, and those looking to capitalize on this new electrified economy are constantly sharing a barrage of information and data on new business models, the projected performance of […]

  • Figure 1. A Honda Pilot following the small overlap front crash test on the driver side. The position of the dummy shows that the driver compartment remained intact. (Source: IIHS.)

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    Aluminum Extrusions Prove Superior in Bumper Systems

    By Andrew Halonen, Mayflower Consulting LLC. The automotive business is rife with change as OEMs introduce new powertrains for hybrid and electric vehicles (EVs). Car companies are also spending billions in big bets on advanced driver assistance systems (ADAS), ride sharing, artificial intelligence (AI), and service businesses in an attempt to shift dollars from the […]