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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.

Audi's Project Artemis woes could delay range of VW Group EVs

Two years ago, Audi's then new CEO Markus Duesmann announced his first big initiative called Project Artemis. The plan's marquee component is "to implement a new lighthouse project for Audi in record time," being "a highly efficient electric car scheduled to be on the road as early as 2024" on a brand new platform that would be shared with Porsche and Bentley. An ex-VW and -Porsche man named Alex Hitzinger, who'd also spent time at Apple working on the tech company's electric car, was brought on board to lead Project Artemis and come up with new ideas. Parent Volkswagen Group said it wanted to become "as agile as in a racing team," removing the bureaucratic molasses and bottlenecks interfering with getting the best product on the road in the best time. However, in any grand venture, failure comes before success. Automobilwoche reports that Artemis is struggling through issues large enough to push the product plans back by years. The issue, as it was with the ID.3 lineup on the eve of that car's launch, is software. Well, that's the latest, largest problem; Artemis has already been through copious struggles before getting to the software bit. Two months after Hitzinger came on, in December 2020, VW raised its EV volume target from 50% to 70% by 2030. That necessitated a rethink of the VW Group's entire platform strategy considering the far greater production scale. Hitzinger only lasted six months in the job, ousted in May 2021, supposedly because Audi believed his ideas were "not suitable for profitable series production" among other reasons. By that time, the pace of software development was already said to be six months behind schedule, with the Car.Software division working on VW.OS 2.0 "not yet running at the speed hoped for." Internal frictions were noteworthy and costly as well. VW's commercial division plant in Hanover was meant to build Artemis vehicles for Audi, Porsche and Bentley, but Automobilwoche reported in January of this year that Porsche paid a ""small three-digit million amount" — like $100 million or so — to get out of the deal mandating its vehicles come from the Hanover facility.    So Audi effectively brought Artemis in-house to lead vehicle development, and Car.Software turned into Cariad to get VW.OS and VW.AC, which stands for Automotive Cloud, to market.  The first Audi vehicle under Project Artemis was planned to arrive by the end of 2024, a production version of the Grandsphere concept.

NHTSA expands new Takata probe to 4 more automakers

DETROIT — The U.S. government's highway safety agency has launched an investigation into four additional automakers that have a potentially deadly type of Takata air bag inflator in their vehicles but have yet to recall them. The National Highway Traffic Safety Administration said in documents posted Thursday that it is investigating Audi, Toyota, Honda and Mitsubishi in connection with a Takata recall involving 1.4 million inflators. This brings the total number of manufacturers potentially impacted to five, as BMW was connected to the issue when it was brought to light earlier in December. The inflators made by the now-bankrupt Takata have a distinct and separate problem that can cause them to blow apart a metal canister and spew shrapnel into people's faces and bodies. The problem killed a driver in Australia who was in an older 3-Series BMW, which has already recalled more than 116,000 vehicles. The problem is so dangerous that in some cases BMW has told drivers to park their vehicles until repairs can be made. The safety agency says in documents that Takata didn't provide details on the affected makes, models or model years of vehicles with the defective inflators. So it is telling the companies to recall them promptly. The agency says that based on when the faulty inflators were produced, it's likely that the vehicles to be recalled came from the 1995 through 2000 model years. In letters to all four automakers, NHTSA says they have five business days to notify the agency after finding out about a safety defect. “If your company has not yet gathered enough evidence to make a determination that the subject air bag inflators present an unreasonable risk to motor vehicle safety, reply with a detailed work plan including the benchmark dates required to make the determination,” the agency wrote in letters to all four automakers dated Wednesday. A Honda spokesman said Thursday it hasn't determined yet whether its vehicles are affected, but a decision should be made soon. Audi, Mitsubishi and Toyota said they are still investigating. NHTSA has told the companies to respond by Jan. 17. On Dec. 4, NHTSA posted documents from Takata and BMW detailing the problems. The documents said the Australian driver was killed, while another Australian driver and a driver in Cyprus were injured. Unlike previous recalls, the Takata non-azide inflators do not use volatile ammonium nitrate to fill the air bags in a crash.