Doc, I wouldn't blame engineers for the composite intakes. Blame politicians and CAFE regulations. Some of the old cast iron intakes might have weighed 40-50 lbs. Given the impact weight has on mileage, every pound in a car is under scrutiny. The new composite intakes weigh about 2 lbs vs. the old cast intakes and aluminum is too expensive for this application. The engineers are between a rock and a hard place, being forced to engineer a solution to a problem created by politicians to a cost dictated by the market.
You have it exactly right! I was hoping someone would point this out.
The fact is that politicians who know nothing, and the new puritans don't know what they are doing. They think they can legislate and hey presto there will be an engineering solution. Well there isn't.
The car makers and engineers need to be honest and say, "this is what will cost to do things properly". The makers have not made a profit on a vehicle since 2004.
If the current mandates proposed are engineered properly, then at a conservative estimate the price scatter of new vehicles needs to be $100,000 to $300,000, and probably more for full electric types to be any good.
I think the way to proceed is to suspend the regs, no EGR, no catalytic converter, no airbags etc, and try and build a reliable vehicle for $7000 to get cash flowing again. At the same time mandate and supervise profits to making new technology mature and affordable. If this is not done, it will be like 1910, with 10% of the population at best able to afford a personal vehicle.
We have to get away from gas and diesel propulsion, it is running out, and time is running out.
If there is no a bold strategy, then the bail out will fail. All the major car companies will go broke. I bought a Toyota Camry hybrid for my wife in September. However Toyota do not make a profit on that vehicle, and its not cheap. So Toyota and Honda will eventually be in the same boat as the American manufacturers. Then you will have the regrowth of the industry from small specialist manufacturers, and cars will cost a small fortune for at least a generation and may be two. That's the way I see it.