You’ve seen them on sports cars and in every car magazine: brake rotors with rows of holes, or with curved slots cut into the surface, or both. Cross drilled and slotted rotors look like something out of a race car — and they kind of are. But here’s the honest truth: for most street drivers,…
If you think 3D printing is just for plastic toys and prototypes, think again. Metal 3D printing, also called metal additive manufacturing, is one of the fastest-growing areas of modern manufacturing. Instead of carving a part out of a block or casting it in a mold, metal 3D printing builds components layer by layer from…
Engines are tough. They’ll happily run for hundreds of thousands of miles, enduring thousands of explosions per minute and temperatures that would melt most materials. But they’re not immortal. When an engine fails, it’s almost always one of a handful of preventable causes — and that’s the good news. If you know what kills engines,…
When you drive over a bump, the springs absorb the impact — and then the car would keep bouncing forever if something didn’t stop it. That something is the shock absorber (or damper). It’s a simple idea — a piston moving through oil — wrapped in remarkably precise manufacturing. Making a shock absorber is a…
Plastic pollution has become one of the defining environmental problems of our time. We produce hundreds of millions of tons of plastic every year, and much of it ends up in landfills, rivers, and oceans, where it lingers for centuries. In response, a new generation of “biodegradable plastics” has arrived, promising to break down naturally…
There’s a small electronic component hiding near each of your wheels that’s smarter than it looks. It’s the ABS sensor — also called the wheel speed sensor — and it’s the eyes of your anti-lock braking system, traction control, and stability control. Every time a wheel turns, this sensor counts its rotation and reports back…
Some arguments never die. Ford vs. Chevy. Manual vs. automatic. And for gearheads with an opinion on everything: cast iron engine block or aluminum engine block? It’s one of the oldest debates in the car world, and unlike most internet arguments, this one has real engineering behind it. Both materials have built millions of engines…
Coil springs are the unsung muscles of your car’s suspension. They hold up the vehicle’s weight, absorb bumps, and keep your tires pressed against the road — all while being twisted and compressed millions of times. Most coil springs outlive the car they’re installed on. But sometimes, one snaps. It usually happens without warning, and…
Every product begins with a deceptively simple question: what should we make it from? The answer determines the cost, the performance, the manufacturing process, the lifespan, and even the environmental impact of the product. Choose poorly, and a brilliant design becomes an expensive failure. Choose well, and an ordinary design becomes a reliable, profitable product….
Somewhere under your car, dozens of small rubber-and-metal parts are quietly doing one of the toughest jobs in the automotive world. They’re called suspension bushings, and they connect the metal parts of your suspension together — control arms, sway bars, struts, and subframes. They’re small, they’re cheap, and when they wear out, your car feels…
