Affordable Injection Molding Transforms Tinkerers Into Tycoons

While everyone is talking about the 3-D printing industrial revolution, Protomold is helping tinkerers become tycoons by making mass-production injection molding technology accessible for easily customized short-run batches — and their recent expansion of materials lets designers produce almost anything they need.

3-D printing something like a cellphone case can take hours — unacceptable when makers need mass quantities. In order to cost-effectively produce products in big batches, traditional manufacturing processes like injection molding are still the best option. Unfortunately, companies that specialize in these processes want to work on huge-volume projects, leaving the little guy, or even a moderately successful Kickstarter project, with few options.

Protomold has stepped in to provide servicing to those makers who need small orders by being able to produce 50-5,000 injection-molded parts in one business day with prices starting at $1,495 for a production tool, and each produced part costing a couple dollars or less. The experience isn't much different than ordering business cards online. A designer uploads their CAD file, chooses from a few preset options, and shelf-worthy injection-molded parts arrive on their doorstep.

The company has been successful, operating since May 1999, while continuing to grow their service. They've just added new materials to their list, including injection molded steel, stainless steel, magnesium, copper. Their newest is the option to mold parts in high temperature, medical grade resins, giving garage entrepreneurs the ability to produce parts for medical devices and high performance applications. Protomold is focused on helping turn big ideas into big companies.

Protomold is able to move so quickly because they optimize their offering for small businesses. While some companies treat moldmaking as an artform, with each production tool cherished like a Toulouse-Lautrec painting, Protomold is more like a Thomas Kincaid canvas used to cover a hole in the wall. This means mold cycle times are a few seconds slower, tools are made out of aluminum instead of steel, and need to be simple enough to be produced on a CNC milling machine. "We can't make everything," says CEO Brad Cleveland. "But the things we can make, we make faster than anyone."

What started as a single engineer looking to solve his own problem has turned into a publicly traded company with a billion dollar market cap and 511 workers filling 160,000 square feet of office space producing parts 24 hours a day.

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Spielberg seen winning director Oscar for “Lincoln”

LOS ANGELES (Reuters) – American filmmaker Steven Spielberg is clear favorite among the public to win the best director award for his film about President Abraham Lincoln at the Academy Awards this year, a Reuters poll showed on Wednesday.

While the race to win best film at the February 24 ceremony was shaken up by “Argo” stealing the thunder of “Lincoln” at two award ceremonies last weekend, the best director statuette was deemed destined for one man.

Spielberg, 66, who has been nominated seven times for best director at the Oscars and won twice – for the World War Two dramas “Schindler’s List” in 1993 and “Saving Private Ryan” in 1998 – was seen as far ahead in the all-male field of five.

A Reuters Ipsos poll of 1,641 Americans found 41 percent thought Spielberg should win and 38 percent said he was most likely to win for his U.S. Civil War-era drama in which British actor Daniel Day-Lewis plays Lincoln.

Almost half of the respondents to the survey conducted Friday through Tuesday were unsure who should or was most likely to be voted best director. The accuracy of the poll uses a statistical measure called a “credibility interval” and is precise to within 2.8 percentage points.

The online poll comes before the Directors Guild of America awards on Saturday in Los Angeles. Since 1948, there have been only six occasions where the winner of the DGA Award for Feature Film has not gone on to win the Oscar for best director.

But this year, the Academy of Motion Picture Arts and Sciences, whose members choose Oscar winners, overlooked the directors of four of the year’s biggest movies – Ben Affleck (“Argo”), Kathryn Bigelow (“Zero Dark Thirty”), Quentin Tarantino (“Django Unchained”) and Tom Hopper (“Les Miserables”) – opening the possibility of a rare split in February in the best film and best director categories.

Betting agencies also have earmarked Spielberg as clear favorite, with William Hill offering odds of 1-5 on Spielberg.

“Our theory is that Spielberg will win best director but not best film,” said Rupert Adams, a spokesman for bookmaker William Hill. “If you listen to what people are saying it is that ‘Lincoln’ is a brilliant film in terms of direction but it is not that exciting to watch unlike ‘Argo.’”

Ang Lee, with his 3-D film adaptation of the best-selling novel “Life of Pi” about an Indian boy adrift at sea with a tiger, was ranked second in the Reuters poll with about one in 10 respondents saying he should or was most likely to win.

The Taiwanese director won the Academy Award for best director in 2005 for the gay-themed Western romance “Brokeback Mountain.”

David O. Russell with the quirky comedy “Silver Linings Playbook” was rated third in the poll with about 5 percent.

The two surprise contenders in the race ranked fourth and fifth: Benh Zeitlin, 30, with his first feature, “Beasts of the Southern Wild,” and Austrian director Michael Haneke with the French-language drama “Armour” about illness and old age.

The exclusion of Bigelow for her film about the hunt for Osama bin Laden has been controversial in the run-up to the 85th Academy Awards. Bigelow, 61, is the only woman to win a best director Oscar, for “The Hurt Locker” in 2009.

Affleck, 40, whose Iran hostage thriller “Argo” swept the board at last weekend’s Hollywood awards shows, was also notable by his absence, as were Hooper and Tarantino. However, all four of their movies are in the running for best film at the Oscars.

(Editing by Jill Serjeant and Belinda Goldsmith)

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Phys Ed: Helmets for Ski and Snowboard Safety

Recently, researchers from the department of sport science at the University of Innsbruck in Austria stood on the slopes at a local ski resort and trained a radar gun on a group of about 500 skiers and snowboarders, each of whom had completed a lengthy personality questionnaire about whether he or she tended to be cautious or a risk taker.

The researchers had asked their volunteers to wear their normal ski gear and schuss or ride down the slopes at their preferred speed. Although they hadn’t informed the volunteers, their primary aim was to determine whether wearing a helmet increased people’s willingness to take risks, in which case helmets could actually decrease safety on the slopes.

What they found was reassuring.

To many of us who hit the slopes with, in my case, literal regularity — I’m an ungainly novice snowboarder — the value of wearing a helmet can seem self-evident. They protect your head from severe injury. During the Big Air finals at the Winter X Games in Aspen, Colo., this past weekend, for instance, 23-year-old Icelandic snowboarder Halldor Helgason over-rotated on a triple back flip, landed head-first on the snow, and was briefly knocked unconscious. But like the other competitors he was wearing a helmet, and didn’t fracture his skull.

Indeed, studies have concluded that helmets reduce the risk of a serious head injury by as much as 60 percent. But a surprising number of safety experts and snowsport enthusiasts remain unconvinced that helmets reduce overall injury risk.

Why? A telling 2009 survey of ski patrollers from across the country found that 77 percent did not wear helmets because they worried that the headgear could reduce their peripheral vision, hearing and response times, making them slower and clumsier. In addition, many worried that if they wore helmets, less-adept skiers and snowboarders might do likewise, feel invulnerable and engage in riskier behavior on the slopes.

In the past several years, a number of researchers have attempted to resolve these concerns, for or against helmets. And in almost all instances, helmets have proved their value.

In the Innsbruck speed experiment, the researchers found that people whom the questionnaires showed to be risk takers skied and rode faster than those who were by nature cautious. No surprise.

But wearing a helmet did not increase people’s speed, as would be expected if the headgear encouraged risk taking. Cautious people were slower than risk-takers, whether they wore helmets or not; and risk-takers were fast, whether their heads were helmeted or bare.

Interestingly, the skiers and riders who were the most likely, in general, to don a helmet were the most expert, the men and women with the most talent and hours on the slopes. Experience seemed to have taught them the value of a helmet.

Off of the slopes, other new studies have brought skiers and snowboarders into the lab to test their reaction times and vision with and without helmets. Peripheral vision and response times are a serious safety concern in a sport where skiers and riders rapidly converge from multiple directions.

But when researchers asked snowboarders and skiers to wear caps, helmets, goggles or various combinations of each for a 2011 study and then had them sit before a computer screen and press a button when certain images popped up, they found that volunteers’ peripheral vision and reaction times were virtually unchanged when they wore a helmet, compared with wearing a hat. Goggles slightly reduced peripheral vision and increased response times. But helmets had no significant effect.

Even when researchers added music, testing snowboarders and skiers wearing Bluetooth-audio equipped helmets, response times did not increase significantly from when they wore wool caps.

So why do up to 40 percent of skiers and snowboarders still avoid helmets?

“The biggest reason, I think, is that many people never expect to fall,” says Dr. Adil H. Haider, a trauma surgeon and associate professor of surgery at Johns Hopkins University in Baltimore and co-author of a major new review of studies related to winter helmet use. “That attitude is especially common in people, like me, who are comfortable on blue runs but maybe not on blacks, and even more so in beginners.”

But a study published last spring detailing snowboarding injuries over the course of 18 seasons at a Vermont ski resort found that the riders at greatest risk of hurting themselves were female beginners. I sympathize.

The takeaway from the growing body of science about ski helmets is in fact unequivocal, Dr. Haider said. “Helmets are safe. They don’t seem to increase risk taking. And they protect against serious, even fatal head injuries.”

The Eastern Association for the Surgery of Trauma, of which Dr. Haider is a member, has issued a recommendation that “all recreational skiers and snowboarders should wear safety helmets,” making them the first medical group to go on record advocating universal helmet use.

Perhaps even more persuasive, Dr. Haider has given helmets to all of his family members and colleagues who ski or ride. “As a trauma surgeon, I know how difficult it is to fix a brain,” he said. “So everyone I care about wears a helmet.”

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BlackBerry 10’s Debut Is a Critical Day for Research in Motion

OTTAWA — Research in Motion’s introduction on Wednesday of a new BlackBerry phone will be the most important event in the company’s history since 1996, when its founders showed investors a small block of wood and promised that a wireless e-mail device shaped like that would change business forever.

Now with just 4.6 percent of the global market for smartphones in 2012, according to IDC, RIM long ago exchanged dominance for survival mode. On Wednesday, the company will introduce a new line of smartphones called the BlackBerry 10 and an operating system of the same name that Thorsten Heins, the president and chief executive of RIM, says will restore the company to glory.

But Frank Mersch, who became one of RIM’s earliest investors after seeing the block of wood, is far less excited by what he sees this time around.

“You’re in a very, very competitive market and you’re not the leader,” Mr. Mersch, now the chairman and a vice president at Front Street Capital in Toronto, said of RIM. “You have to ask: ‘At the end of the day are we really going to win?’ I personally think the jury’s out on that.”

The main elements of the new phones and their operating system are already well known. Mr. Heins and other executives at RIM have been demonstrating the units for months to a variety of audiences. App developers received prototype versions as far back as last spring.

While analysts and app developers may be divided about the future of RIM, there is a consensus that BlackBerry 10, which arrives more than year behind schedule, was worth the wait.

Initially RIM will release two variations of the BlackBerry 10, one a touch-screen model that resembles many other phones now on the market. The other model is a hybrid with a keyboard similar to those now found on current BlackBerrys as well as a small touch screen.

The real revolution, though, may be in the software that manages a person’s business and personal information. It is clearly designed with an eye toward retaining and, more important, luring back, corporate users.

Corporate and government information technology managers will be able to segregate business-related apps and data on BlackBerry 10 handsets from users’ personal material through a system known as BlackBerry Balance. It will enable an I.T. manager to, among other things, remotely wipe corporate data from fired employees’ phones while leaving the newly jobless workers’ personal photos, e-mails, music and apps untouched. The system can also block users from forwarding or copying information from the work side of the phone.

Messages generated by e-mail, Twitter, Facebook, instant messaging and LinkedIn accounts are automatically consolidated into a single in-box that RIM calls BlackBerry Hub.

Charles Golvin, an analyst with Forrester Research, called the new phones “beautiful” and described the operating system as “a giant leap forward” from RIM’s current operating system. Ray Sharma, who followed RIM’s glory years as a financial analyst but who now runs XMG Studio, a mobile games developer in Toronto, has been similarly impressed.

But both men are among many analysts who question the ability of BlackBerry 10, whatever its merits, to revive RIM’s fallen fortunes.

“If it’s good, it will help inspire the upgrade cycle,” Mr. Sharma said. “But it has to be great in order to inspire touch-screen users to come back. If it’s good, not great, I will be concerned.”

Mr. Golvin was more blunt. “They’ll need to prove themselves in the face of a simultaneous onslaught of marketing from Microsoft, not to mention the continued push from Apple plus Google and its Android partners,” he wrote. “This is a gargantuan challenge for a company of RIM’s size.”

In the year since he took over from the founders, Jim Balsillie and Mike Lazaridis, Mr. Heins has certainly remade RIM. He cut 5,000 jobs in a program to reduce operating costs by about $1 billion a year. Along the way, he also replaced RIM’s senior management and straightened out its balance sheet. While unprofitable, RIM remains debt-free and holds $2.9 billion in cash.

With BlackBerry 10, RIM not only started over with its operating system, it also rebuilt the company through acquisitions. Its core operating system comes from QNX Software Systems, the design of the user interface is largely the work of the Astonishing Tribe in Sweden while other main components, like the touch-screen technology, came from smaller companies that are now part of RIM.

Integrating all of those acquisitions, analysts and former RIM employees say, added to the delays that plagued BlackBerry 10.

Now that the new phones are finally here, Mr. Heins is counting on RIM’s remaining base of 79 million users globally to eagerly upgrade. But where those customers reside may be as important in their numbers in determining the success of that plan.

In the United States, which leads the world in setting smartphone trends, about 11 million BlackBerry users switched to other phones between 2009 and the middle of last year, according to an analysis by Horace Dediu on Asymco, a wireless industry blog he founded.

Until the final months of 2012, RIM continued to increase its subscriber base through sales of low-cost handsets to less developed countries like Nigeria and Indonesia. Although BlackBerry 10 will be made available worldwide, the initial phones will be too expensive for a majority of BlackBerry fans in those regions.

RIM may also have confused its loyalists, particularly in North America and Europe, in the run-up to the BlackBerry 10 debut. Many of those users stuck with BlackBerrys because of their physical keyboards. But public demonstrations for BlackBerry 10 were centered on the touch-screen-only version and its virtual keyboard.

While some corporations have remained loyal to BlackBerry, RIM not only has to sell them on the new handsets, it also must persuade them to upgrade server software to accommodate the new operating system, a costly and time-consuming process. Companies whose employees continue to use older BlackBerrys will have to run two separate BlackBerry servers.

Mr. Heins’s pitch to those corporations is that the BlackBerry 10 server software will also allow them to manage and control data on employees’ Android phones and iPhones. But any corporation or organization that allows those phones to connect with its systems long ago installed mobile device management software from other companies, including Good Technology and SAP. RIM is likely to find that the competition in device management software is as severe as it is in the handset business.

This article has been revised to reflect the following correction:

Correction: January 30, 2013

An earlier version of this article misstated part of the name of the Toronto company where Frank Mersch is the chairman and a vice president. It is First Street Capital, not Front Street Capital. An earlier version of this correction misspelled Frank Mersch’s surname as Mersh.

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Sheriff's response time is longer in unincorporated areas, audit finds

It took Los Angeles County sheriff's deputies a minute longer to respond to emergency calls from unincorporated parts of the county than from cities that contract with the department for police services, according to a county audit.

The finding comes days after Supervisor Gloria Molina accused Sheriff Lee Baca of "stealing" police resources from residents in unincorporated neighborhoods and threatened to hire "independent private patrol cars" to backfill cuts in sheriff's patrols. She has accused Baca of providing better service to contract cities than to unincorporated areas.

According to the audit, which examined the last fiscal year, it took deputies, on average, 4.8 minutes to respond to emergency calls in contract cities compared with 5.8 minutes in unincorporated areas.

Sheriff's officials said the extra minute was because neighborhoods in unincorporated areas are more spread out and have more difficult road conditions.

The audit also found that Baca provided 91% of promised patrol hours to unincorporated areas, compared with 99% for cities and agencies that buy his services. Sheriff's officials blamed the difference on deep budget cuts imposed by the board that caused the department to leave dozens of deputy positions unfilled.

Adjusted for those cuts, the department was much closer to its goal — averaging 98.5% fulfillment of its pledged patrol hours, according to the audit.

The findings by the county's auditor-controller are expected to add more fuel to the ongoing debate between the sheriff and the board about whether the sheriff is shortchanging county residents who live outside city borders.

Baca and his predecessors have long wrangled with supervisors over funding and patrol resources.

Although the board sets the sheriff's budget, Baca, an elected official, has wide discretion on how to spend it. The Sheriff's Department polices about three-fourths of the county. Along with the unincorporated areas, Baca's deputies patrol more than 40 cities within the county that don't have their own police forces. The patrol obligations for those cities are set in contracts with the department, so county budget cuts are more likely to affect unincorporated areas.

On Tuesday, the board is expected to discuss Molina's idea to empower unincorporated neighborhoods to negotiate police contracts with the Sheriff's Department or some other agency — the same way incorporated cities do.

According to the audit, it costs the sheriff about $552 million to provide police services for contract cities and agencies, but the department gets approximately $371 million back. The auditor-controller suggested pursuing changes in state law or board policy to allow the sheriff to recoup more.

State law prohibits sheriffs from billing contract cities for non-patrol services provided countywide. So the department has provided a broad range of services — such as homicide and narcotics detectives, bomb squads and the county crime lab — at no extra charge.

Sheriff's spokesman Steve Whitmore said those rigid agreements — with contract cities, the county's courts, community colleges and public transit lines — limited where the sheriff could slash in the face of county budget woes.

The board has cut the sheriff's budget — now at $2.8 billion — by $128 million in 2010, $96 million in 2011 and $140 million last year, according to Whitmore.

The sheriff has already reassigned about two dozen gang enforcement deputies to patrol in unincorporated areas and has identified more than 90 other deputies to do the same, Whitmore said.

Molina's spokeswoman declined to suggest other areas where sheriff's officials should slash in light of funding cuts from the board but said that services to unincorporated areas should not be one of them.

"We respectfully request they go back to the drawing board," spokeswoman Roxane Márquez said.

robert.faturechi@latimes.com

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How Science Invented a Remarkable New Harder-Than-Diamond Nanomaterial

How do you design industrial tools that can top the most heavy-duty diamond-tipped devices? Easy: you create a new material that’s even harder than diamond.

Yes, it’s an oft-misstated “fact”: Diamond is the hardest material in the world. That title has been contested for some time now, and a paper published this month in Nature offers yet another contender.

“Ultrahard nanotwinned cubic boron nitride,” describes how researchers from the University of Chicago, the University of New Mexico, Yanshan University, Jilin University, and Hebei University of Technology compressed a form of boron nitride particles to an ultrahard version.

The transparent nuggets that resulted rivaled — and even exceeded — diamond in their hardness, according to tests run by the researchers. With a Vickers score of 108 GPa, it surpasses synthetic diamond (100 GPa) and more than doubles the hardness of commercial forms of cubic boron nitride.

The secret is in the nanostructure. Yongjun Tian and the other researchers started with onion-like boron nitride particles shaped a bit like a flaky rose — or, as Tian describes them, like Matryoshka dolls. When they compressed them at 1,800 Celsius and 15 GPa (around 68,000 times the pressure in a car tire), the crystals reorganized and formed in a nanotwinned structure.

In a nanotwinned crystalline structure, neighboring atoms share a boundary, the way neighboring apartments do. And like some apartments, the twins mirror each other. Typically, to make a substance harder, scientists decrease the size of the grains, which makes it harder for anything to puncture it — small grains equals less space between them for any point to enter. But the process hit a wall: in anything smaller than about 10 nm, inherent defects or distortions are nearly as big as the grains themselves, and thus weakens the structure.

But the nanotwinning also makes substances harder to puncture, and in the case of boron nitride, maintained that characteristic strength at sizes averaging about 4 nm, explains Tian. And as a bonus, the cubic boron nitride was stable at high temperatures as well.

“In our nanotwinned cBN, the excellent thermal stability and chemical inertness are maintained with hardness competitive to or even more than diamond, making it the most desirable tool material for industry,” says Tian.

He anticipates that, with further research, the product will be comparable in price to the softer, commercial forms of cubic boron nitride that are currently available. Probable uses include machining, grinding, drilling and cutting tools, as well as scientific instrumentation.

Of course, the problem is, to accurately measure the hardness of a material, scientists take an even harder substance, shape it into a pyramid, and see how much pressure is required to drive that pyramid into the material. That doesn’t work unless you have something you’re sure is harder, so the Vickers number for Tian’s cubic boron nitride is not necessarily the final word on the measurement, notes crystallographer Natalia Dubrovinskaia in Scientific American.

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Philadelphia opera co.: New name, new vision

PHILADELPHIA (AP) — The Opera Company of Philadelphia is getting a name change that officials say is in better harmony with its move toward more innovative programming and greater diversity in its repertoire.

The company said Tuesday it will now be known simply as Opera Philadelphia. The new name and logo will appear on all of its brochures and ads.

The announcement was made in conjunction with the unveiling of the 2013-2014 season.

The company plans to continue bringing opera to new audiences with surprise “pop-up” concerts in famous Philadelphia locations. Past performances at a downtown Macy’s and the Reading Terminal Market have received millions of views on YouTube.

Opera Philadelphia says it has five new operas in development and aims to present challenging contemporary works along with classics like “Carmen” and “La Boheme.”

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Well: Celery Recipes for Health

For many people, celery is best used as a garnish, part of a snack tray or perhaps to stir a Bloody Mary. But to Martha Rose Shulman, the Recipes for Health columnist, celery can be a main course. She writes:

I’m a big fan of celery, both raw and cooked, as the main ingredient or as one of several featured ingredients in a dish. You can do the traditional thing with raw celery and dice it up and add it to a potato, tuna or egg salad, or you can make a celery salad, slicing the branches as thin as you can get them and tossing them with herbs, radishes, oil and vinegar, and blue cheese. If you are cooking with celery, don’t stop at one branch when you make soup. The celery contributes a wonderful herbal flavor dimension. It retains its texture for a long time when you cook it, so I used it as the main vegetable in a risotto and loved the way it stood up to the creamy rice.

Here are five ways to move celery off the snack tray and on to center plate.

Lentil, Celery and Tomato Minestrone: With extra celery, traditional minestrone soup takes on a whole new layer of flavor.

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Pan-Cooked Celery With Tomatoes and Parsley: A way to serve celery as a side dish, or as a topping for grains or pasta.

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Celery and Radish Salad With Gorgonzola: Use the delicate hearts of celery for this light and delicious salad.

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Celery Risotto With Dandelion Greens or Kale: Celery contrasts nicely with the rice in this aromatic risotto.

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Puréed Broccoli and Celery Soup: A broccoli soup with an added dimension of flavor.

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Appeals Court Suspends Peugeot's Job-Cut Plan

PARIS — PSA Peugeot Citroën, the struggling French automaker, has been ordered by an appeals court to temporarily halt carrying out its plan to shed workers in France. But the company said the ruling would not affect its overhaul in the long run.

Lionel Bonaventure/Agence France-Presse — Getty Images

Striking workers at the P.S.A. Peugeot Citroën plant in Aulnay-sous-Bois, France, on Monday.

The Paris Court of Appeals partially overturned a September decision by a lower tribunal, agreeing with a union complaint that Peugeot had failed to adequately discuss its revamping plans with workers at Faurecia Intérieurs Industries, an auto parts maker in which it owns a majority stake.

The appeals court reached the decision Monday, but did not make it public until Tuesday.

The appeals court held that Faurecia — which is also seeking to cut jobs — must formally consult with its workers before Peugeot can begin putting its own plan into effect. Faurecia said Tuesday that it would begin the consultation process “without delay.”

A Peugeot spokesman, Pierre-Olivier Salmon, said the decision would have little practical effect on the company's plans because “we’re only in the negotiation phase now, anyway.” The appeals court left untouched the tribunal’s dismissal of the union’s request to overturn Peugeot’s restructuring plan.

Peugeot is battling to regain its footing in a European auto market that shrank by more than 8 percent last year. It is particularly vulnerable to the slump because it does not have a large presence in high-profit luxury vehicles and is dependent on the European market, including southern European countries that have been badly dented by the sovereign debt crisis.

The company said last year that it would close its plant in Aulnay-sous-Bois, near Paris, and was aiming to cut 8,000 jobs of the roughly 97,000 people it employs in France. Peugeot said it hoped to achieve the staff cuts mainly by offering early retirement and buyouts. It has also said it will not replace some other departing workers as it seeks to reduce its total French work force by around 11,200 jobs by mid-2014. Strikes and other industrial actions have become common, with union employees on Monday interrupting production at the Aulnay facility for a time.

The French company last year sold a 7 percent stake to General Motors, which has its own problems in Europe with its struggling Adam Opel unit. The two companies have formed a loose alliance to cooperate on vehicle projects and logistics.

Peugeot’s legal setback serves to illustrate the difficulty of streamlining operations in France, particularly in an industry that the government views as a strategic priority amid wide concerns for the country’s competitiveness. President François Hollande, a Socialist, has said Peugeot restructuring plan was “not acceptable.”

Monday’s ruling also shows how seriously courts here take companies’ legal obligations to workers. Earlier this month, a court threw out the overhaul plans of Le Crillon, a landmark luxury hotels in Paris, just months before it was to close for a two-year renovation. The hotel’s owner, the tribunal found, had failed to adequately consult with its 360 employees.

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'Argo' producer scours for the next stranger-than-fiction story

Hunched over a desk in his spartan Westwood apartment, David Klawans squints at his computer monitor and knits his brow in concentration. "I'm perusing," he says.

His eyes dart between headlines almost indecipherable on a Web page displaying about 800 stamp-sized images of newspapers from 90 different countries.

"Two kids running? What's that?" he exclaims before clicking on a photo. "Oh, it's refugees. Whatever. Moving on."

SAG 2013: Winners | Quotes | Photo Booth | Red carpet | Backstage | Best & Worst

Nearly every day, for upward of 10-hour stretches, the independent film producer speed-reads police blogs, articles from RSS feeds and niche-interest journals in dogged pursuit of an elusive prize: a story on which to base his next movie.

His biggest hit to date is "Argo." Before the film landed seven Oscar nominations (including one for best picture) and two Golden Globes (including best drama picture), before it generated more than $180 million in worldwide grosses, "Argo" existed as a declassified story in the quarterly CIA journal Studies in Intelligence, which Klawans happens to have been perusing one day in 1998.

"It's like going on the beach with a metal detector," the self-described news junkie says of his process. "Like Kanye West looks through records to sample on his songs, I'm looking for stories to turn into films."

Klawans, 44, has established himself as Hollywood's least likely movie macher by heeding the advice of his mentor, the old-school producer David Brown ("Jaws," "A Few Good Men"): "Read everything you can get your hands on."

Indefatigable in his quest to root out oddball, overlooked true-life stories, Klawans spins material most others ignore into cinematic gold.

OSCAR WATCH: "ARGO"

"Argo" took nearly 14 years to reach the big screen after Klawans read about CIA exfiltration expert Tony Mendez's rescue of six American diplomats hiding in Tehran during the 1979 Iran hostage crisis. Mendez (portrayed in the movie by "Argo's" director, Ben Affleck) posed the group as Canadian filmmakers scouting locations for a science-fiction film, created a fictitious production company and planted articles about the bogus project in Hollywood trade papers.

Throughout the '90s Klawans was scraping by as a production assistant for an L.A.-based Japanese TV commercial firm. He didn't own a car, so he bicycled to UCLA's magazine archive to check the story. In microfiche files, he came across the CIA's planted articles in the Hollywood Reporter and Variety from January 1980. "My jaw dropped," he says.

Problem was, Mendez already had representation at Creative Artists Agency and was preparing to publish a memoir, "The Master of Disguise." Even so, Klawans persuaded Mendez to let him attempt to set up a movie project. He eventually bought the rights to Mendez's life story as well.

OSCARS 2013: Nominations

"I'm cycling to pitch meetings wearing a backpack with a change of clothes. It's summertime and I'm sweating. And I'm getting to know studio security. They call me 'bike boy,'" remembers Klawans, who would switch from bike to business attire outside the studio gates. "I would basically throw my backpack behind a bush — I was embarrassed to look like a messenger guy."

The New York University film school graduate was born in Chicago. His family moved to Belgium when he was 2 and he grew up in Europe and the U.S. consuming a steady diet of sci-fi and fantasy films including "Star Wars."

He came close to setting up the "Argo" project as a cable TV movie. But when that deal fell through, Klawans says, "it hit me that Tony had planted stories in Variety and Hollywood Reporter as a cover. For the CIA, it's all about illusions and perception. I thought, 'That's what I'm going to do. I'm going to plant an "Argo" story in a magazine.'"

The producer had met former L.A. Weekly staff writer and "This American Life" contributor Joshuah Bearman through friends who thought the two shared an appreciation for offbeat material. Bearman also had experience turning a magazine story into a movie; an article he reported for Harper's became the 2007 documentary "The King of Kong: A Fistful of Quarters," about two die-hard video game players vying for the world's highest score in the vintage arcade game "Donkey Kong."

Klawans handed over his research and contacts to Bearman and proposed that the journalist write "Argo" as a magazine article that would entice movie backers.

Bearman landed an assignment from Wired magazine, then interviewed everyone he could: Mendez, officials in the State Department with knowledge of the exfiltration and Ken Taylor, the Canadian ambassador to Iran who housed some of the fugitive American diplomats, as well as the six embassy "houseguests."

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