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Researchers halfway to cutting carbon fiber costs by 90%

Carbon fiber has been utilized for decades to build racecars, as a means to cut weight while maintaining strength. But until recently, the space-age material has been largely absent from the street on anything but supercars because of the expense to use it. Recently, BMW signaled a major shift in that trend when it starting using carbon fiber reinforced plastic panels on the i3 and i8. This relatively small scale start might be just the beginning; the German company believes that a breakthrough to inexpensively manufacture the lightweight stuff is just on the horizon.
MAI Carbon Cluster Management GmbH counts BMW, Audi, Airbus, the German government and many other organizations as supporters, and it's researching how to make carbon fiber cheaper to produce, according to Automotive News Europe. The company thinks it can reduce costs by 90 percent in the near future. "We've certainly reached a halfway point on our cost-cutting target for suitable carbon-fiber parts," said project head Klaus Drechsler to Automotive News Europe.
Unfortunately, it isn't entirely clear just what MAI Carbon is doing to make such a huge leap possible. However, a recent post on the company's website talks about a new form a carbon fiber using a thermoplastic matrix that could be cured in less than three minutes. That's compared to about 90 minutes in the traditional process with an autoclave.

BMW makes X7 in Spartanburg official

BMW has made it official - there will be a flagship crossover called X7, and it will be built right here in the US of A. The announcement was made today, confirming rumors of the new model at the Spartanburg, SC factory that broke earlier this week.
"Plant Spartanburg was built to enhance and expand the BMW lineup, underscoring the BMW Group commitment to the United States" said Dr. Norbert Reithofer, chairman of the BMW board of management in a statement. "In addition to the X3, X5, X6, and the new X4, we are today announcing another all-new, larger X model to be manufactured exclusively at this plant for our world markets: the X7."
BMW will spend $1 billion by 2016 upgrading its South Carolina factory, which already produces the X3, X5 and X6. The plant is currently capable of producing 300,000 units per year, but with the big investment from BMW, capacity will climb to 450,000 units. 800 jobs will be added as a result of the investment and new and upcoming models.

BMW i8's three-cylinder sounds like it's shaping up quite nicely

We've run across some rather interesting news... or perhaps we should say interesting sounds. The folks from Bimmerpost have scrounged up a short video showing a preproduction BMW i8 running through a few gears in Sport mode at a quick pace, and if you were concerned that the somewhat eco-friendly nature of the upcoming German sports car would neuter its ability to stir the aural senses, fret not.
Judging by the lovely noise coming from the engine compartment of the i8 in the video, BMW's expertise in tuning high-strung, small-bore engines - remember, BMW Motorrad has quite the penchant for well-conceived motorcycle engines - has come through loud and clear. Now, it's worth mentioning that BMW's controversial Active Sound technology will be included with the i8, so the production car may not sound exactly like this version, which is running with the tech disabled. Owners won't have the ability to disable Active Sound on production i8s.
In related news, Bimmerpost reports that BMW will equip the i8 with an external Active Sound Design system to go along with its Pedestrian Protection System. That means those on the outside will likely hear piped engine recordings from the rear and a sort of "howl" from the front in order to warn pedestrians that the otherwise quiet (when running on electricity, that is) car is approaching. It will also feature technology that can stop the car before contacting a pedestrian.