Abstract: A powder bed fusion system includes a powder bed including a build surface and a vacuum system. The vacuum system includes a collection device positioned over the build surface. The collection device includes a body, a pathway defined in the body, wherein the pathway ends in a passageway opening, and a particle retainer connected to the body near the passageway opening. A method of forming a component includes forming a layer of unfused metal powder on a powder bed with a recoater, introducing gas to the powder bed and applying a vacuum with a collection device, fusing a portion of the layer of unfused metal powder on the powder bed with a heat source to form a component layer and generating contaminants, collecting the contaminants from the powder bed with the gas and the vacuum applied by the collection device.

Abstract: A system for predicting a door opening event of a vehicle includes an identity recognition device associated with an individual occupant profile. The system also includes one or more controllers in electronic communication with the identity recognition device, where the one or more controllers store one or more individual occupant profiles in memory of the one or more controllers that includes historical occupant behavior exhibited by one or more occupants associated with the identity recognition device. The one or more controllers execute instructions to determine a predetermined condition has occurred, where the predetermined condition indicates the vehicle is undergoing a potential engine off event. The one or more controllers determine a door opening event probability value based on at least the gear position probability value and the engine off probability value.

Abstract: Presented are feedback control systems for monitoring battery system hardware, methods for making/operating such systems, and vehicles with wireless battery management systems (WBMS) governed through distributed feedback control. A method of operating a WBMS includes a wireless-enabled manager device selecting a batch of cell module assemblies (CMA) within the WBMS to communicate with to thereby retrieve data for their respective battery modules. A manager access control list (ACL) is created with respective media access control (MAC) addresses and ID data for the selected CMAs. A wireless connection is established between the manager device and a respective cell monitoring unit (CMU) for each selected CMA based on the corresponding MAC addresses and ID data in the manager ACL. The manager device downloads, from the CMU of each selected CMA, device data for each battery modules associated with the selected CMA. The manager device then switches the operating mode for each CMU.

Abstract: A sunshade system of vehicle roof includes a sunshade formed from a fabric material including a plurality of pleats arranged across a lateral sunshade width and extending along a sunshade length. At least one sunshade guide extends along a length of the sunshade and retains a lateral width edge of the fabric material, and guides the sunshade along a path between a stowed position and an extended position. The sunshade has a variable sunshade width along the sunshade length in the extended position by expansion and relaxation of the plurality of pleats.

Abstract: A layered catalyst structure for purifying an exhaust gas stream includes a catalyst support and a palladium catalyst layer including an atomic dispersion of palladium ions electrostatically adsorbed onto an exterior surface of the catalyst support. The catalyst support includes an alumina substrate, a first ceria layer disposed on and extending substantially continuously over the alumina substrate, and a second colloidal ceria layer formed directly on the first ceria layer over the alumina substrate. The palladium catalyst layer is formed on the exterior surface of the catalyst support by applying a palladium-containing precursor solution to the exterior surface of the catalyst support and then heating the catalyst support and the palladium-containing precursor solution. The palladium-containing precursor solution includes a positively charged palladium complex in an aqueous medium and has a pH greater than a point of zero charge of the second colloidal ceria layer.

Abstract: Methods and systems are provided for continuously producing cast metal components. An exemplary method includes feeding molten metal into a first mold at a fill station; maintaining a pressurized chamber at an elevated pressure; moving the first mold into the pressurized chamber, wherein the molten metal solidifies in the first mold under the elevated pressure; and removing the first mold from the pressurized chamber.

Abstract: A method for identifying a cell quality during cell formation includes: conducting a beginning of life cycling following an initial cell formation charge of multiple cells; collecting and preprocessing a discharge data set generated by one of the multiple cells during the beginning of life cycling; calculating a statistical variance from the discharge data set identifying an estimated probability of meeting a target cell usage time; and projecting a life span of the multiple cells.

Abstract: A smart glass display includes a first glass layer, a second glass layer, a display layer, an auto-shading layer and a control module. The display layer is disposed between the first glass layer and the second glass layer and includes an array of light emitting diodes and at least one ambient light sensor. The at least one ambient light sensor is configured to detect a level of ambient light at the display layer. The auto-shading layer includes suspended particle devices each of which configured to selectively provide different levels of transparency. The control module is configured to, based on an output of the at least one ambient light sensor, adjust a transparency level of at least a portion of the auto-shading layer.

Abstract: A shoe-clip fastener for securing components in a vehicle includes a stop member having a wall portion and a slot defined in the wall portion and an insertion element coupled to the stop member. The insertion element includes a base member and a clip member cantilevered from the base member. The clip member includes an actuator section that projects proudly of the slot.

Abstract: In exemplary embodiments, methods and systems are provided for a digital flashlight for a vehicle. In another exemplary embodiment, a system is provided that includes a display of a vehicle; and a processor coupled to the display of the vehicle and a camera of the vehicle and configured to at least facilitate: obtaining a camera image frame via the camera of the vehicle; determining a first region of the camera image frame having a first brightness level; determining a second region of the camera image frame having a second brightness level that is greater than the first brightness level; and providing instructions to the display of the vehicle for displaying the first region with increased brightness that is based on the second brightness level.

Abstract: A plunger for die casting may include a front injector end made of an iron alloy including, by mass: about 1% to about 6% nickel, about 0.1% to about 5% copper, about 0.2% to about 2.5% aluminum, about 0.5% to about 2% manganese, and about 0.05% to about 0.2% carbon. The iron alloy may be formed into an initial shape of the front injector end, heated to a temperature greater than or equal to about 900° C. and then cooled to form a supersaturated solid solution of iron and dissolved alloying elements. Then, the iron alloy may be heated at a temperature sufficient to precipitate intermetallic nanoparticles from the supersaturated solid solution to form an intermetallic precipitate phase dispersed throughout an iron-based matrix phase. A chemical compound layer may be formed at and along a surface of the iron alloy by exposing the iron alloy to an oxygen-containing and/or nitrogen-containing environment.

Abstract: Presented are multi-pulse fuel injection systems for monitoring engine fuel injectors for missed pulses, methods for making/using such systems, and vehicles equipped with such systems. A method of operating a fuel injection system includes an engine controller determining if the system's injectors are operating in a multi-pulse mode for injecting multiple fuel pulses per combustion cycle to an engine's cylinders and, if so, monitoring pulse signals transmitted to the injectors for injecting the multiple fuel pulses. For each combustion cycle for each injector, the controller flags a cylinder misfire if any one of the fuel pulses for that combustion cycle is missed. For each cylinder, the controller calculates a misfire ratio of a total number of cylinder misfires to a total number of combustion cycles; if one of these misfire ratios exceeds a calibrated misfire limit, the controller commands a resident subsystem to execute control operations to mitigate the misfires.

Abstract: A multifunctional self-cleaning surface layer and methods of preparing the multifunctional self-cleaning surface layer are provided. The multifunctional self-cleaning surface layer includes an inorganic matrix including silicon and oxygen; a plurality of photocatalytic active particles distributed within and bonded to the inorganic matrix; and a plurality of nanopores defined within the inorganic matrix in regions corresponding to bonds between the plurality of photocatalytic active particles and the inorganic matrix. Water molecules may be disposed within at least a portion of the plurality of nanopores. In the presence of water and electromagnetic radiation, the plurality of photocatalytic active particles may facilitate a decomposition reaction of any oil or organic residue on the multifunctional self-cleaning surface layer.

Abstract: In various aspects, the present disclosure provides a component. The vehicle component includes a polymer matrix, a plurality of fibers in the polymer matrix, and a heating element embedded in the polymer matrix. The heating element may be (i) a discrete heating element, (ii) at least a portion of the plurality of fibers, or both (i) and (ii). The heating element is configured to be coupled to an external circuit to generate heat. In one aspect, the vehicle component is a vehicle header including an elongated body extending between a first side and a second side.

Abstract: A system for managing a fleet of electric vehicles and respective fleet drivers includes a command unit having a processor and tangible, non-transitory memory on which instructions are recorded. The command unit is adapted to obtain input variables, including respective fleet tasks and their priority status. Route data for the respective fleet tasks is obtained. The command unit is adapted to obtain an objective function defined by a plurality of influence factors having respective weights. The command unit is adapted to obtain optimal charging schedules respectively for the electric vehicles and match the respective fleet tasks to the electric vehicles and the respective fleet drivers, based in part on the objective function, input variables and the route data. The influence factors may include energy cost optimization, timeliness of task completion and minimizing range anxiety. In some embodiments, the respective weights of the influence factors are designated by a fleet manager.

Abstract: A negative electrode for an electrochemical cell that cycles lithium ions includes a particulate component embedded in a polymeric matrix component that comprises polytetrafluoroethylene. The particulate component includes a plurality of composite particles, with each of the composite particles having a core and a selective barrier layer disposed on a surface of the core. The core of each of the composite particles includes an electroactive negative electrode material. The selective barrier layer of each of the composite particles is formulated to prevent or inhibit electrochemical reactions from occurring between lithium stored in the electroactive negative electrode material of the core and the polytetrafluoroethylene in the polymeric matrix component.

Abstract: A method for fabricating wide and continuous double-sided lithium metal anodes includes thermally evaporating lithium to form first and second continuous lithium layers on respective first and second continuous polymer substrates, so as to form respective first and second continuous lithium/polymer sheets. The first and second continuous lithium/polymer sheets are laminated onto respective top and bottom surfaces of a continuous metallic substrate, which may be made of copper, with the first and second continuous lithium layers being disposed in direct contact with the respective top and bottom surfaces to form a continuous polymer/lithium/metal/lithium/polymer structure. The first and second continuous polymer substrates are then removed from the continuous polymer/lithium/metal/lithium/polymer structure to provide a continuous lithium/metal/lithium anode structure.

Abstract: Systems and methods are provided for generating alignment parameters for processing data associated with a vehicle. In one embodiment, a method includes: receiving image data associated with an environment of the vehicle; receiving lidar data associated with the environment of the vehicle; processing, by a processor, the image data to determine data points associated with at least one pole identified within image data; processing, by the processor, the lidar data to determine data points associated with at least one pole identified within the lidar data; selectively storing the data points as data point pairs in a data buffer; iteratively processing, by the processor, the data point pairs with a plurality of perturbations to determine a transformation matrix; generating, by the processor, alignment data based on the transformation matrix; and processing future data based on the alignment parameters.

Abstract: An electromagnetic interference shielding composite. The electromagnetic interference shielding composite includes a polymer substrate formed into a shape of a packaging component. The composite further includes an electromagnetic interference layer contacting the polymer substrate and a conductive coating contacting the electromagnetic interference layer. An integrated power electronic module includes packaging including the electromagnetic interference shielding composite. A method of forming the electromagnetic interference shielding composite for an integrated power electronic module includes molding a polymer substrate into a shape of a packaging component, forming an electromagnetic interference layer on the polymer substrate, and forming a conductive coating on the electromagnetic interference layer.