It’s 350º F under the hood of a stockcar. Throw in high vibrations (up to 600 g) and high electrical current demands (up to 140 A) and it’s not surprising that the alternator is said to be one of the most problem-prone parts in NASCAR engines. So in an effort to improve alternator temperature cooling (they can’t do much to adjust the velocity forces nor the electrical requirements), NASCAR approved routing a 1-in duct from the side of the radiator shroud to the alternator in 2009. While that was a helpful move, it presented problems for packaging under the hood.

Earnhardt Childress Racing (ECR), the engine manufacturing joint venture between racing organizations Dale Earnhardt Inc. and Richard Childress Racing, attempted to achieve the cooling duct by putting a secondary rear cover with a hose attachment onto the alternator. But the cooling efficiency was reduced by maintaining the original Bosch alternator cover. So ECR engineers, having learned of a polyamide-based material reinforced with carbon fibers during attendance at a motorsports expo in Italy, began using it to develop prototype replacement covers. The material, Windform XT from CRP Technology, allowed them to create the covers via rapid prototyping. However, because the material is partially conductive and because the packaging considerations were so tight as to not permit any electrical isolation, it they determined it couldn’t used for the application.

However, the time investment wasn’t lost because CRP had recently developed a material that is reinforced with glass fibers, Windform LX, which also exhibits strength and thermal resistance. So six alternator covers were initially created and track tested, showing a 20º F reduction in stator motor temperature and excellent durability. Rapid prototyping then turned to rapid production as 50 covers were created for installation onto the alternators in ECR NASCAR Cup engines. In 12 races, not one alternator failed. That’s engineering for reliability in extreme conditions.

This year’s winner of the Starbucks-sponsored Betacup Challenge open design contest—which had the goal of creating a new, eco-friendly coffee cup—isn’t a cup.

That’s right: the winner of the contest didn’t design a new cup.

Rather, the winner, “Karma Cup,” is a simple concept: A chart near the counter will track those who bring in reusable cups for their coffee. The 10th customer to order coffee with a reusable cup gets theirs free. So while it’s not a redesigned coffee cup as most of the other 400-plus entries were, this idea could promote coffee shop sustainability in an equally effective way.

Many coffee shops already offer incentives for people that bring in reusable cups—normally in small discounts on their coffee—but they’re widespread use has yet to catch on. So the Karma Cup is hoping greater incentives will inspire more people to think sustainably. Think of it as a community-oriented rewards program where only those with reusable cups can be a part of the club.

The Karma Cup may not be as exotic of an idea as, say, the “Neutral Resource Coffee Cup,”—made from the leaves of the Pacific Island-based Areca Palm Tree—but sometimes simpler is better. And faster for adoption.

Here lies Anne Lindeboom. Born in 1920, she was a loving mother and she loved to garden and sew. Dead in 1984, now, she’s a toaster.

On a level of “Tales from the Crypt”-like creepiness, Dutch artist Wieki Somers has been using human ashes to create sculptures by means of 3D printing. Disturbing? Unquestionably, but Somers has a point in doing this. She says there’s too much excessive consumption in the world. So turning loved ones into everyday household objects will make people appreciate them more.

While it may be a valid point, we can’t imagine grandpa would be too thrilled about becoming a table lamp.

No, this isn’t some hip car remodeling show coming to MTV, but an open innovation contest to help develop an infotainment system of the future. In order to research the potential use of apps for a next-generation vehicle infotainment system prototype, Volkswagen wants to collect as many new ideas as possible. That’s where you come in. You can upload your apps in a SWF file, share your ideas or provide input on someone else’s idea. And not only could your app be in a future VW, but you could win cash prizes.

Application programs can be submitted for these categories:

• Eco mobility
• Games and fun
• Networking and communication
• Productivity
• Travel utilities

The contest ends June 30.

XCOR Aerospace made a leap into the space tourism industry with the development of its Lynx suborbital spacecraft, as you may recall from a previous edition of Time Compression. But that’s not all XCOR has done to accelerate out-of-this-world travel. Although less exotic than a spaceplane, perhaps, XCOR has worked for the past eight years in developing better piston pumps for space applications. Most recently, in association with United Launch Alliance (ULA), it developed a liquid hydrogen piston pump over a four-month period using rapid prototyping techniques.

So what’s the benefit of the piston pump vs. the more commonly used turbopumps? Longer life, lower costs, lighter weight and the ability to operate over a wider range of speeds, all of which are important for implementation into the private space sector.

What better way to distinguish your company from others than by developing innovative products? However, not all companies actually do that. So the government of Singapore has decided to do something about it. It’s offering tax incentives for innovative design projects in Singapore.

Yes, government has budgeted a tax incentive over a five-year period for innovative industrial and product design projects as a means to establish more competitive businesses. The incentive is good for up to 250% of total income. After approval of the project, companies must complete the design process and develop an end product resulting in new intellectual property within two years to qualify. After all, those tax breaks have to have some deliverable.

It pays to be innovative, especially in Singapore

King Tut has been dead since 1343 B.C., but soon his creepy, decayed, mummified corpse will be resurrected in New York City. Well, kind of. To make the Discovery Times Square Exposition unique, organizers decided to have a replica of the famed golden king’s mummy created for display. Here’s a look at how King Tut was created for his “Big Apple” debut using Materialise software and 3D printers:

Word is that Brendan Fraser isn’t allowed within 100 yards of the mummy replica.

Consumers have been burning manufactured fire logs made from recycled wood and sawdust since the 1960s as a healthier and more accessible alternative to cordwood, so you’d think a new log of the likes wouldn’t be too noteworthy. But this log from VIASPACE isn’t your typical run of the mill log: It’s made from grass.

Yes, grass. But not just any grass, Giant King Grass—a fast-growing crop that can be harvested multiple times a year and potentially used as a material for biofuels. Said to be the cleanest burning manufactured log, the “Green Log” has a zero net-carbon footprint and is binded with natural wax and palm oil as a fire starter, rather than petroleum products, which are known to produce carbon emissions.

There’s yet to be word, however, on if the log affects the taste of s’mores.

If you thought the only way to clear a congested artery was through high-pressure angioplasty, think again. Medical tool developer Cardiovascular Systems has developed a “sanding” device that breaks up plaque from inside a blood vessel.

That’s right: A sanding device. The tool is the Diamondback 360, and it works as its crown rapidly rotates against plaque buildup inside a blood vessel to break it into particles smaller than red blood cells, restoring blood flow within minutes. It was designed using SolidWorks software—3DVIA Composer to formulate design and animation and Simulation Premium to optimize the performance of plastic components—in nine months, half the time compared to its previous design methods.

Now that’s giving the 10 million Americans that suffer from poor limb circulation a more convenient way to enjoy those little things in life again.

Generally when you think of applications for plastic, bags, bottles and small appliances may come to mind—not something like a railroad bridge, especially one capable of withstanding a whopping 130 tons of weight.

You read correctly: A plastic railroad bridge.

It’s the case in Fort Eustis, VA., home to the U.S. Army Transportation Corps, where two short-span railroad bridges were constructed from a plastic developed by alternative infrastructure materials firm Axion International. The material is a recycled structural composite (RSC) solution consisting almost entirely of post-consumer and industrial plastic.

We’ve yet to hear word on how the conductor feels about the bridge, however.