This article comprises a description of methods of internal combustion engine cylinder machining including a description of traditional machining method and a description of some new machining methods – being in use in the motor industry. Special attention has been given to a laser beam treatment method. Results of cylinder surface structure examination after laser-beam treatment with an electron microscopy method and with the use of a scanning microscope have been always presented.

It is the employer's responsibility to ensure safe working conditions by determining occupational risk at all workplaces, combating sources of danger, and providing employees with relevant information and instructions. This is one of the effective ways to reduce the number of accidents at work. The purpose of the article is to analyze accidents at work in the period 2014-2018 in a selected foundry enterprise in Wielkopolska. The scope of the article includes a summary of the data from the Central Statistical Office, the characteristics of the enterprise, and the hazards occurring in the foundry process. An analysis and assessment of accident rates at the foundry in the same period were also presented. The assessment was based on accident rates, on the basis of which the work station most vulnerable to accidents was determined.

The main directions of changes in new internal combustion engine designs are determined not only by legislation on the toxic components emission in the exhaust gases, but also by the changes resulting from technological development, which are the results of research and development activities. One of the basic systems that has undergone intensive development recently is the piston-rings-cylinder (PRC) node. This article contains an original analysis of the direction of changes in cylinder surface shaping in terms of the cylinder's main functional features in the PRC system (the casting material and the opening surface topography after the finishing process). The results of the research on cast iron materials for cylinder liner castings with strength of R m > 300 MPa were analyzed based on the centrifugal casting method and their finishing stage in the finishing process meeting the criteria for reduction of oil consumption and particle emissions for new HDD type engine designs. The author also points to innovations in surface structure metrology based on new 3D optical measurement methods and the quality rating method by Mercedes company.