Hybrid cars are a great way to save fuel and contribute to saving the environment at the same time. Battery technology is one way to improve current offerings. Another way to improve on fuel savings is to maximize the efficiency of the gas engine, whether this gas engine is linked or not to a hybrid powertrain.

Properly controlling the amount of fuel and the exact location where the fuel is being introduced to the engine is one area where most manufacturers and suppliers are focusing their research. Direct injection of the fuel is key to these improvements.

Delphi Automotive announced today that the company has been awarded a $3.7 million grant from the U.S. Department of Energy (DOE) to develop a highly-versatile, energy-efficient method for micro-machining complex shapes. Utilizing ultrafast laser technology, the new manufacturing process will enable enhanced production of flow control holes in Delphi’s gas direct injection (GDi) fuel injectors.

This process will increase laser machining energy efficiency up to 25 percent over standard practices while eliminating secondary processes such as etching, deburring or surface cleaning.

Delphi is partnering with Raydiance, Inc. and Microlution, Inc. in the development of this new system. The project’s prototype platform will be developed and verified at Delphi’s Rochester facility.

Once mastered, this technology will allow more precise production of fuel injectors and thus, better control the exactitude of fuel delivery to the engine’s combustion chamber.