From Lab to Exhaust: A Startup’s Breakthrough in CO2 Transformation

Alicja Stankiewicz, CTO, Coat-It
Marek Turkiewicz, CEO, Coat-It

Pollution kills more people globally each year than war, hunger, or disease. And at the heart of this crisis is carbon dioxide (CO2) – the primary greenhouse gas driving climate change.But what if CO2 could be split and transformed before it ever leaves a tailpipe?

That’s the vision behind RainIons, a U.S.-based startup that has developed a revolutionary powder capable of reducing greenhouse gas emissions – including CO₂, NOx, and hydrocarbons – by transforming them into safe, stable molecules. The application of technology is currently being developed further by COAT-IT, a Polish startup specializing in the engineering of high-temperature-resistant coatings tailored for practical automotive applications.

The Science Behind the Solution

The innovation combines pyroelectric and piezoelectric minerals with naturally occurring radioactive materials (NORM) in a conductive matrix. This unique blend emits alpha particles, negative ions, and electrons – without external power. These particles ionize pollutants and split strong molecular bonds, including those in CO₂.

Independent studies and internal evaluations suggest the solution can significantly reduce CO₂ emissions across a variety of conditions. At elevated temperatures (around 500 °C), reductions have been observed above of 50 %. Even in lower temperature environments (70 – 200 °C), meaningful decreases in CO₂ – typically within a 25 – 30 % range – have been noted, with no harmful byproducts identified. In moisture-rich settings, reductions of up to 50 % indicate that water may play a catalytic role in the
transformation process.

From Tourmaline to Transformation

Inspired by earlier research on tourmaline-infused asphalt, the tourmaline-based “negative ion powder” was infused into a conductive coating and applied it to a diesel muffler. FTIR spectroscopy revealed that CO₂ was being split into graphite and oxygen, with water concentration directly influencing reaction efficiency.

What’s Next?

COAT-IT is now developing durable, high-temperature coatings for commercial deployment. The next phase includes real-world trials using diesel engines and custom exhaust systems. The goal: to quantify transformation products and optimize substrate design for maximum pollution reduction.

If successful, this technology could redefine emissions control – turning exhaust systems into active climate solutions.

Data Driven Cost Measure Generation for Automotive Systems Using Teardown Intelligence and AI

Ivan Jovanovic, Team Leader Incubation InnoHub

Cost optimization in modern drivetrain systems requires more than benchmarking—it demands structured, data driven ideation. This article presents an AI supported methodology that leverages largescale teardown intelligence to systematically generate and assess cost measures at component and system level. The approach bridges the gap between engineering detail and cost strategy decision-making.

Introduction

Automotive drivetrain systems are undergoing rapid transformation driven by electrification, increasing system complexity, and mounting cost pressure. Engineering teams are expected to identify cost reduction opportunities earlier and with greater confidence, while preserving performance, quality, and compliance. Traditional cost

engineering approaches—often based on expert workshops, static benchmarks, or manual analysis—struggle to scale with the growing volume and complexity of available technical data.

This article presents a structured, data driven approach for generating cost measures for systems using largescale teardown intelligence combined with AI supported analysis. The methodology is designed to support engineers and cost analysts in identifying, structuring, and prioritizing cost measures based on factual technical evidence rather than assumptions or isolated examples.

Technical Challenge

Teardown databases today contain thousands of components, materials, manufacturing processes, and architectural design choices across vehicle generations and OEMs. While this data provides a rich foundation for cost insights, extracting actionable cost measures remains challenging due to:

• High data volume and heterogeneity
• Limited traceability between design choices and cost impact
• Dependence on individual expertise to formulate improvement ideas
• Difficulty comparing alternative technical solutions at scale

As drivetrain architectures evolve—especially in electrified powertrains—there is a growing need for systematic methods that transform teardown data into concrete, reusable cost measures.

Methodology

The presented approach is based on three core technical pillars:

1. Structured Teardown Intelligence Componentlevel teardown data is normalized across materials, geometries, manufacturing processes, and system architectures. This enables cross vehicle and cross-generation comparisons within subsystems.
2. Cost Measure Pattern Identification Historical teardown data is analyzed to identify recurring cost relevant design patterns, such as material substitutions, part integration, geometry changes, or process shifts. These patterns are abstracted into reusable cost measure templates that are independent of a single vehicle or OEM.
3. AI Supported Ideation and Filtering An AI based engine combines teardown evidence, cost drivers, and engineering constraints to generate potential cost measures. Measures are contextualized by vehicle segment, drivetrain type, and system boundaries, allowing relevance filtering and prioritization based on feasibility and expected impact.

Concrete Example: Evidence Based Part Elimination

Teardown analysis reveals that the removal of the external brand logo on the hood—first observed on the Tesla Cybertruck and later adopted on recent Model Y versions—constitutes a validated example of part elimination for cost optimization. This decision removes a complete component and associated assembly steps, improving manufacturing efficiency and reducing part count. Such ground truth examples enable data driven challenges to traditional design choices, while highlighting that radical cost measures often require longer internal alignment despite their technical simplicity.

Achieved Innovation

The key innovation lies in shifting cost measure generation from an experience driven activity to a repeatable, data supported process. Instead of manually deriving ideas from individual benchmarks, engineers can explore a structured set of cost measures grounded in real, observed design solutions.

For drivetrain systems, this enables:

• Faster identification of technically realistic cost measures
• Improved transparency between design decisions and cost impact
• Better reuse of historical teardown learnings across projects
• Support for early phase concept and target setting activities

The approach does not replace engineering judgment; rather, it augments it by providing a technically substantiated starting point for cost discussions and design trade-offs.

Conclusion

As drivetrain technologies continue to evolve, cost engineering must evolve in parallel. Leveraging teardown intelligence through structured data models and AI supported ideation offers a scalable way to generate high-quality cost measures rooted in real engineering solutions. This methodology supports more informed, fact-based decisionmaking and helps bridge the gap between technical design and cost strategy in modern automotive development.

Husco Automotive: Engineering Solutions That Move Mobility Forward

Steven Musbach, Account Manager

Husco Automotive is a global engineering and manufacturing partner delivering advanced actuators, valves, and fluid control solutions for automotive applications across internal combustion, hybrid, and electrified vehicle platforms. With decades of systems‑level expertise, Husco collaborates closely with OEMs and Tier 1 integrators to develop production‑ready technologies for driveline, engine, and transmission applications—delivering improved efficiency, durability, and functional performance. As a production partner, Husco offers uniquely engineered solutions across a broad product portfolio, supported by world‑class supplier sourcing and vertical integration advantages.

Husco Automotive’s portfolio includes a range of precision‑engineered solenoids, actuators, and thermal management devices designed to deliver efficient, reliable control across critical automotive applications:

• Ring solenoids engineered for fast response, low power consumption, and robust performance across demanding automotive duty cycles
• Transmission valve sets delivering precise hydraulic control for modern transmission systems where efficiency, repeatability, and reliability are critical
• Motor actuators specifically designed to meet vehicle application requirements, improving system efficiency and overall vehicle performance across conventional and electrified platforms
• Driveline disconnects engineered to smoothly and quietly engage and disengage at the wheel end, axle, transfer case, or differential—reducing efficiency losses while maintaining durability and a seamless driving experience

Learn more about our full product lineup at Husco.com/Automotive.

Husco Automotive’s engineering teams work directly with customers to develop application‑specific solutions that integrate seamlessly within each vehicle system. With deep expertise in electro‑hydraulic and electro‑mechanical design, system modeling, validation, and production readiness, Husco engineers collaborate from early concept through launch—aligning performance, packaging, durability, and manufacturing requirements. This close engineering‑to‑engineering partnership enables Husco to operate

as an extension of the OEM team, accelerating development cycles while delivering solutions optimized for real‑world application demands.

Husco has developed a world class supply chain capable of supporting global, USMCA, and Tier‑N supply models to provide partners with reduced supply chain risk at competitive pricing.

Vertical integration is a core element of Husco’s manufacturing strategy, highlighted by in-house coil winding operations, injection molding capabilities, and dedicated automation design and manufacturing teams. These integrated competencies enable optimized production flows, faster lead times, competitive pricing, and manufacturing strategies uniquely tailored to each program.

Through cutting-edge engineering, a world-class supply chain, and vertically integrated manufacturing, Husco Automotive delivers scalable, production-ready solutions that help customers meet performance, efficiency, regulatory, and supply-chain requirements—while positioning their vehicles for the future of mobility.