Delphi Automotive has been awarded a $3.7 million grant from the U.S. Department of Energy to develop a versatile, energy-efficient method for micromachining complex shapes, according to the company.

Using ultrafast laser technology, the new manufacturing process will enhance production of the flow-control holes in Delphi’s (GDIs) gas direct-injection fuel injectors.

This process will increase laser machining efficiency up to 25 percent over standard practices and eliminate secondary processes such as etching, deburring and surface cleaning, the company reports.

Delphi, a supplier of electronics and other devices for automotive and commercial vehicles, is partnering with femtosecond laser technology developer Raydiance Inc., Petaluma, Calif., and Chicago-based machine tool manufacturer Microlution Inc. to develop the system. The project’s prototype platform will be developed and verified at Delphi's Rochester, N.Y., facility.

“This project has energy-saving implications and applicability across numerous industries and our working relationship with the Department of Energy is critical to advancing these important initiatives,” said Jeffrey Owens, chief technology officer of Delphi Automotive.”