BASF and Toyota Motor North America Research & Development achieved lightweighting success with the new 2021 Toyota Sienna. The vehicle, scheduled to launch later this year, just won the prestigious Altair Enlighten Award for achievements in vehicle weight savings for reduced mass of the third row seat.
In the previous model, the third-row seat was comprised of 15 different steel components, making it very heavy. Toyota wanted the 2021 Sienna’s third seat to be lighter and cost competitive while exceeding all performance criteria. Toyota turned to BASF to help them achieve their lightweighting goal.
“Lightweighting doesn’t always have to be more expensive,” said Todd Muck, from the Toyota Technical Strategic Planning Office at the Toyota R&D Center in Saline, Michigan. “We were able to meet our cost objective and saved 15% compared to the prior generation. The seat is 30% lighter compared to the previous model. We had some great partnerships that helped us achieve these targets, one of which was BASF.”
Traditionally, resin components for seating have had metal reinforcement, which can add more cost to the process. Toyota also wanted an injection molding part that was a shoot-and-ship part – meaning it was made in one piece, without complex and costly post-processing. That’s where BASF’s expertise in materials and design came in. BASF used its unique 35% glass-reinforced and impact-modified polyamide PA6 grade Ultramid® B3ZG7 CR, and its proprietary computer aided engineering (CAE) tool ULTRASIM® which allowed for an accurate CAE simulations during the multiple phases of development efforts.
“The third seat design is what I would classify as an enabling technology,” said Matt Parkinson, Manager Applications Development Engineering and Composite Technologies, BASF Performance Materials. “It is the first of its kind in the way it is designed without inserts as a fully injected seat back. One of the challenges was to ensure a high elongation and impact qualities for the crash requirements. At the same time, we focused on strength and stiffness because the seat also serves as a load floor.”
“BASF helped us bridge the challenge gap for this seat back and meet our targets,” said Muck. (MT)
NB: Photo is representational.
Force Motors Launches AI-powered Connected Vehicle Platform, Sets Up Command Centre In Pune
- By MT Bureau
- August 05, 2025
Pune-headquartered automotive major Force Motors has unveiled Force iPulse, its new connected vehicle platform designed to enhance operational intelligence and vehicle lifecycle management.
Developed in partnership with Intangles, the platform uses state-of-the-art artificial intelligence (AI) and hybrid analytics to provide insight into vehicle performance. It continuously analyses high-resolution data to predict issues, enabling the early detection of performance problems and component failures.
Unlike traditional monitoring systems, Force iPulse goes beyond simply reporting faults. It performs root-cause analysis on key subsystems, including the engine, powertrain and electrical and thermal systems, allowing for proactive intervention to prevent unplanned downtime. This enables fleet operators to make precise, data-backed decisions.
Prasan Firodia, Managing Director, Force Motors, said, “At Force Motors, we believe in value-driven innovation, and this launch is yet another step in our mission to deliver superior, intelligent mobility solutions. Force iPulse is more than just a technological solution—it is a business enabler for our customers. It brings in transparency, improves efficiency, and ensures safety across operations, thereby equipping our customers with complete control over their fleet operations. We are confident that this new initiative will be well appreciated by both our customers as well as our partners and help take us another step forward in delivering our promise of customer delight.”
The platform, built on a secure cloud-native architecture, provides access to real-time and historical vehicle data on both mobile and desktop devices. It offers a unified view of operations, helping fleet managers detect inefficiencies, enforce best practices and optimise the total cost of ownership.
Furthermore, to support the new technology, Force Motors has established an Intelligence Command Centre at its headquarters in Pune. Manned by diagnostics experts, the centre provides remote vehicle monitoring, alert management and expert guidance. This is backed by a 24x7 support infrastructure.
Force iPulse is now available across Force Motors’ network of more than 300 dealerships. It will be a standard feature on all new commercial vehicles and can also be fitted as a certified aftermarket solution.
Faraday Future Begins Trial Production Of FX Super One MPV In California
- By MT Bureau
- August 04, 2025
California-based e-mobility company Faraday Future Intelligent Electric has commenced the trial production phase of its new FX Super One electric MPV at its Hanford facility.
The phase will focus on validating production processes, workflows and quality standards. Factory engineers and staff are also undergoing training to prepare for full-scale production. The next stage will involve engineering validation, including safety testing.
Unveiled in Los Angeles on 17 July, the FX Super One features Faraday Future’s Super EAI F.A.C.E. interface and its 6x4 Embodied AI Agent architecture. The model is positioned as a premium alternative to traditional large SUVs like the Cadillac Escalade.
The company has invested around USD 300 million in its 1.1 million-square-foot Hanford facility, which could be scaled up to produce over 30,000 vehicles per year with further funding and permits. The plant may also support multi-model assembly lines.
Faraday Future recently secured USD 105 million in new funding, expected to cover most of the FX Super One’s launch costs.
Founded in 2014, the company aims to disrupt the automotive industry by creating a user-centric, technology-first and smart driving experience.
Schaeffler Introduces Radar-Based Hands-Free Vehicle Access Sensor
- By MT Bureau
- August 04, 2025
German tier 1 supplier Schaeffler has developed a hands-free access sensor that allows users to open and close vehicle trunks or sliding doors with a foot motion, without needing to press a button or use a remote. Based on Doppler radar technology, the system enables keyless and contactless vehicle access.
According to Matthias Zink, CEO Powertrain & Chassis, Schaeffler AG, “With the expanded portfolio of the Powertrain & Chassis Division, Schaeffler is positioning itself as a new provider of innovative sensor solutions for body applications. The hands-free access sensor is an example of Schaeffler’s growing, complementary product range following the merger with Vitesco Technologies – and marks another step toward our goal of becoming the world’s leading Motion Technology Company.”
The sensor activates when a person enters the radar field beneath the rear of the vehicle. It detects foot movements and analyses both speed and direction within a 60-centimetre range. Artificial intelligence is used in the calibration process, adapting the system to different vehicle models to improve detection accuracy and reduce false triggers.
Production of the sensor began in Europe at the end of 2024 for major automotive manufacturers.
Leif Reinhold, Head of the Powertrain Solutions Business Division at Schaeffler, responsible for the company’s sensor portfolio, said. “Schaeffler’s hands-free access sensor is a key component in the vehicle for intuitive access and also highlights our expanded sensor expertise in the market. We have been producing the hands-free access sensor in volume since the end of 2024 – in Europe, for major European automotive manufacturers. We also see additional growth potential in North America and China.”
Operating at a 24 GHz frequency, the sensor maintains performance in various weather conditions and temperatures ranging from –40 to 105 degrees Celsius. It connects to vehicle systems via a LIN interface and is suitable for various body styles including SUVs, minivans and sedans.
The sensor can be mounted either on the bumper or the chassis and is compatible with vehicles fitted with or without a trailer hitch. Installation involves a single screw-in component, removing the need for extra clips, brackets or antenna runs.
Maruti Suzuki India Charts Ambitious Future With Expanded Focus On EVs, Drones, Mobility Solutions & Sustainability
- By MT Bureau
- August 01, 2025
In a clear signal of its strategic intent to diversify and future-proof its business, Maruti Suzuki India’s Board of Directors have agreed to amend its Memorandum of Association (MoA) to enable expansion into a wide array of new-age mobility, sustainability and technology-driven segments.
The amendments go beyond just manufacturing and selling passenger vehicles, and now includes buses, vans, lorries, motorcycles, scooters and other motor-powered vehicles, as well as amphibious vehicles and those capable of travel on land, sea, air or any combination thereof. The scope also covers the production and sale of drones, unmanned aerial vehicles (UAVs) and unmanned aircraft systems (UAS), along with all associated components, accessories and technologies.
Additionally, the company may establish and operate facilities for testing, training and data processing to support its manufacturing and technology-driven activities.
The amended charter outlines a significantly broadened scope, allowing the company to manufacture and deal in a comprehensive range of vehicles – from traditional automobiles to drones, unmanned aerial systems (UAS) and amphibious vehicles. This move opens up potential entry into emerging sectors such as aerial mobility and defence-grade UAV systems.
A key focus area is the electric mobility ecosystem. Maruti Suzuki India plans to develop and operate EV charging and battery swapping infrastructure, as well as engage in trading and distribution of alternative fuels such as compressed biogas and hydrogen. This aligns with India's push towards decarbonisation and adoption of cleaner transport.
On the sustainability front, Maruti Suzuki India aims to build capabilities in recycling and repurposing end-of-life vehicles (ELVs) and industrial scrap, including metals, plastics and e-waste. It also plans to trade in carbon credits and renewable energy certificates, suggesting a move to integrate environmental instruments into its business model.
The amendments also allow Maruti Suzuki India to offer consultancy and R&D services in vehicle engineering, testing and certification, while supporting clients and regulators with testing grounds and infrastructure. Additionally, it can now provide supply chain, logistics and IT services – potentially transforming into a full-spectrum mobility and services enterprise.
With this expansive update to its foundational objectives, Maruti Suzuki India is preparing to transition from a conventional automotive business into a multifaceted mobility and sustainability-focused organisation, capitalising on upcoming opportunities in electrification, circular economy and next-gen transport.
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