Breaking the Bottleneck | Issue 48
[5/6/2024] Recyclable PCBs, Intel Deep Dive, Tesla Gigacasting on Pause, & More!
Breaking the Bottleneck is a weekly manufacturing technology newsletter with perspectives, interviews, news, funding announcements, manufacturing market maps, and a startup database!
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Content I Enjoyed Last Week 🏭🗞️🔬 📚
News:
These Recyclable Circuit Boards Could Stem E-Waste [IEEE Spectrum]
Researchers have engineered recyclable PCBs using a polymer known as vitrimer, allowing these new boards to be repaired and their materials recovered and reused. Conventional PCBs, composed of thermoset polymers, pose environmental challenges due to their non-recyclability. In contrast, vitrimers feature reversible chemical bonds, enabling them to be recovered and reused without damage. Treating vitrimer-based PCBs with a specific solvent allows the polymers to be separated, facilitating the reuse of components like chips, copper, and glass fibers. The vitrimer-based PCBs exhibit comparable electronic and mechanical properties to traditional ones and are compatible with existing manufacturing processes. This breakthrough introduces a new technological capability for recycling PCBs, potentially fostering circularity in the electronics supply chain. Notably, vitrimer-based PCBs can be repaired due to the self-healing properties of vitrimers, offering a sustainable alternative to the current practice of discarding cracked PCBs. This innovation could revolutionize electronic design, promoting the development of modular devices that can be upgraded rather than discarded.
The Robot Race is Fueling A Fight For Training Data [MIT Tech Review]
While robots have traditionally relied on equations and code for training, the advent of AI is revolutionizing this paradigm, allowing robots to glean insights from data akin to how language models assimilate vast textual repositories. However, the scarcity and complexity of real-world data present formidable challenges. Leading companies and research institutions are engaged in an intense race to devise novel methodologies for data collection, spanning from teleoperation techniques to collaborative open-source initiatives like the Distributed Robot Interaction Dataset (DROID), which boasts over 350 hours of meticulously curated human-generated data. Moreover, a compelling discourse within the robotics community regarding the efficacy of real-world data versus simulated environments for training purposes exists. While cutting-edge simulators such as Nvidia's Isaac Sim offer promising alternatives, they grapple with the persistent "sim-to-real gap," necessitating further refinement.
Tesla Shrinks its Gigacasting Manufacturing Ambitions [Verge]
Traditionally, automakers assemble underbodies from numerous individual parts. However, Tesla sought to revolutionize this process by utilizing giant presses to die-cast large sections, aiming for a fully integrated underbody. This approach aimed to streamline manufacturing and drastically reduce costs. Tesla also introduced the "unboxed" manufacturing process, in which parts are assembled separately in dedicated areas before final integration, promising accelerated production and cost reductions. However, Tesla's ambitious plan has been postponed amidst declining sales and profits. The company has reverted to its existing manufacturing process, which is used for the Model Y and Cybertruck, where the underbody is composed of three sections: two gigacasted front and rear sections and a mid-section made from aluminum and steel, housing the battery. The company's Q1 report suggested that next-generation models would leverage new and existing platforms, potentially sharing manufacturing lines with current vehicles.
Intel’s $28 Billion Comeback: Inside Ohio [Bloomberg]
Ohio One represents Intel's most ambitious endeavor. CEO Patrick Gelsinger envisions it as the world's largest chip factory, signaling Intel's commitment to technological advancement and economic resurgence. Gelsinger emphasizes the project's critical role in America's economy and national security, stating, "I just view this as existential to our economy, to our national security." The company has pledged $28 billion to build Ohio One, aiming to manufacture state-of-the-art chips crucial for smartphones and AI technology. Politicians, including President Joe Biden, have lauded the Ohio One project, positioning it as a centerpiece of the nation's economic policy. The US government has pledged significant financial support, with a $19.5 billion subsidy package under the Chips and Science Act. Intel's Ohio project comes amid the company's efforts to reclaim its technological leadership in the face of stiff competition and financial challenges. Intel's struggles in recent years, including declining market share and manufacturing setbacks, have underscored the urgency of its Ohio venture. Gelsinger acknowledges the difficulties ahead, describing the endeavor as "hard, multiyear, heavy, expensive," but expresses confidence in Intel's ability to succeed, noting, "we've done it before." However, Ohio One's success hinges on Intel's ability to secure major clients and compete with industry rivals like TSMC and Samsung.
How Machining Makes AM Successful [Modern Machine Shop]
Innovative 3D Manufacturing in Franklin, Indiana, has achieved consistent profitability in metal part production and prototyping through additive manufacturing (AM) by focusing on preventing build failures and closely integrating AM with CNC machining. The company, specializing in laser powder bed fusion (LPBF), rarely experiences build failures, even with most non-recurring jobs. This success rate is attributed to overspecifying support structures and adding stock around 3D-printed features, reducing the risk of part distortion. By leveraging vertical machining centers, Innovative 3D can easily support LPBF work and minimize machining costs downstream. In addition to machining, close customer relationships have been pivotal, driving repeat business and referrals. The company's consultative approach helps customers optimize part designs for AM, ensuring cost-effectiveness and functionality. The company's expertise in AM has also led to opportunities for bridging supply chain gaps by producing parts through LPBF rather than casting, resulting in improved material properties and shorter lead times.
China’s Electric Cars Keep Improving, a Worry for Rivals Elsewhere [NY Times]
Chinese automakers are driving innovation in the electric vehicle (EV) sector, spearheading a new era of more significant, technologically advanced cars poised to outpace global rivals. With 71 new battery-electric models to hit the market this year, China's automotive landscape is profoundly transforming. These next-gen EVs boast taller hoods for a bold aesthetic, enhanced storage capacity, and improved braking thanks to larger tires. Moreover, manufacturers prioritize passenger comfort with thicker, more comfortable seats, while advancements in battery technology enable faster recharging and increased power. Central to China's EV dominance are breakthroughs in battery technology, exemplified by CATL's latest battery boasting a 10-minute charge for a range of 370 miles. Moreover, advancements in battery efficiency allow for smaller batteries, freeing up interior space for enhanced passenger comfort and larger back seats with increased legroom. Chinese automakers also redefine automotive design aesthetics, opting for larger, more luxurious front ends and embracing sharper, edgier designs. This departure from lightweight aluminum in favor of steel alloys enables cost-effectiveness without compromising visual appeal. While the emphasis on electric propulsion continues to grow, Chinese manufacturers are attentive to consumer preferences, offering plug-in hybrids alongside pure electric options. Looking ahead, Chinese EVs are set to penetrate the lucrative U.S. market, with companies like Geely exporting models like the Polestar 2 despite facing tariffs. This strategic expansion underscores China's ambition to assert dominance beyond its borders, challenging established players and reshaping the future of the automotive industry.
Research:
Achieving Robust Closed-loop Control in Remote Locations [AWS]
Kelvin, an industrial automation software company, leverages closed-loop control to optimize asset performance across various industries such as energy, oil and gas, manufacturing, mining, and renewable energy. Closed-loop control, a fundamental technique in system control engineering, involves continuous monitoring of system outputs and making adjustments based on feedback to achieve desired performance. Traditional closed-loop systems relied on programmable logic controllers (PLCs), but AI-driven control systems necessitate edge computing infrastructure for broader data access and processing capabilities. Kelvin addresses communication challenges inherent in distributed edge systems by implementing a robust edge-cloud communication mechanism. The architecture comprises Kelvin Cloud, deployed on AWS, for centralized management and analytics, and Kelvin Nodes, edge runtimes for local processing and control. Three levels of edge communication are enabled: on-edge, edge-to-cloud, and edge-to-edge ensuring secure, reliable, and low-latency data transmission. The customer impact of Kelvin's solution is exemplified by a deployment optimizing over 250 unconventional gas wells, resulting in a remarkable 10-times return on investment (ROI) primarily from production gains.
Chart of the Week:
Podcasts/Video:
How CHIPS Act Money Got Awarded
Manufacturing Deals🏭💵
Arris Composites - An advanced manufacturer with a technology enabling the highest-performing fiber-reinforced composites
$34 million [Venture] - From Engineering, Zebra Technologies, Standard Industries, Vertex Exploratory Fund, NEA, XN, Taiwania Capital, Bosch Ventures, Modern Venture Partners (MVP), and Alumni Ventures Group (AVG).
Thintronics - A company reinventing interconnect insulator technologies to unlock next- generation computing, networking and wireless performance
$23 million [Series A] - Led by Maverick Capital and Translink Capital
Deltia AI- A German startup that uses AI and computer vision to optimize picking processes in warehouses & manufacturing sites
$4.3 million [Seed] - Led by Cavalry Ventures and joined by Merantix
LiNova Energy - A company developing ultra-high-energy batteries utilizing a Polymer Cathode
$15.8 million [Series A] - Led by Catalus Capital and joined by Saft
Insane Cyber - A company building a platform to protect, detect, and respond to industrial cybersecurity threats
$4.2 million [Seed] - Led by Paladin Capital Group
Planned Downtime 🏭🧑🔧
Rabbit R1 Review