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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 spotted testing new S4 at the Nurburgring

Where there's smoke, there's fire. Only in this case, the smoke is the upcoming new Audi A4, and the fire is the S4 spotted undergoing testing in this latest batch of spy shots. Snapped in both sedan and Avant wagon forms while undergoing testing on and around the Nurburgring – where else? – the next-generation Audi S4 will of course be based on the new A4 that's anticipated to debut in Frankfurt this September. That means MLB Evo architecture and styling that takes a page out of the new TT's playbook. But in S4 trim, it'll be altogether more performance oriented. Expect an even more powerful version of the outgoing model's 3.0-liter supercharged V6, pumping out a good 340-350 horsepower to all four of its driven wheels. That power will help it keep pace with the new Mercedes C450 AMG Sport. It won't have to take on the new C63 AMG directly, though, as that'll be the job of the next RS4 that will slot above it. But since that model may never make it to US showrooms, this will stand as the flagship of the new A4 family as far as the American market is concerned. Related Video:

Audi RS3 Sportback is the hottest hatch

Fans of compact, European vehicles that mix luxury and performance should be in paradise right now. There's already the 320-horsepower M235i from BMW and the 355-hp CLA45 AMG (or A45 elsewhere) from Mercedes-Benz, but you can now add one more to the list. Meet the Audi RS3 Sportback, which boasts 362 hp and five doors, too. With propulsion coming from Audi's turbocharged 2.5-liter five-cylinder that makes 343 pound-feet of torque (465 newton-meters), the RS3 Sportback can scramble to 62 miles per hour in 4.3 seconds. Top speed is limited to 155 mph, but buyers can opt to raise that top end to 174 if desired. The inline-five is mated to a seven-speed S-tronic dual-clutch gearbox, sending power to the ground via Quattro all-wheel drive with torque vectoring, which can send between 50 and 100 percent of the power to the rear wheels as needed. To cope with the boosted output, the suspension has been lowered by an inch compared to the standard A3 Sportback, and magnetic dampers are a further option. Buyers can also tick the box for carbon-fiber-ceramic brake rotors at the front. The RS3 goes on a diet its latest iteration, too, weighing 121 pounds less than its predecessor. While buyers get potent power, Audi keeps the looks understated. The exterior wears a front airdam with larger openings and some aluminum flourishes, and a diffuser at the back gets some more matte trim. A roof spoiler and aluminum look for the mirror housings add a few other touches to catch the eye. Inside, all versions get sport seats covered in Nappa leather and a flat-bottom steering wheel wrapped in leather and Alcantara. But for the really sporty look, buyers can spec optional RS buckets with a carbon shell that weigh 15 pounds less than the standard units. European deliveries of the RS3 Sportback begin in the summer. Autoblog reached out to Audi spokesperson Mark Dahncke who told us there are currently "no plans to bring it to the US." Scroll down to read Audi's full announcement of this five-door hot hatch. Power in compact form – the new Audi RS 3 Sportback Ingolstadt, 2014-12-12 Sporty top model of the A3 model series Most powerful production five-cylinder in RS history with 270 kW (367 hp) 0 – 100 km/h (62.1 mph) in 4.3 seconds – 0.3 seconds faster than the previous model Hot, throaty sound, exhilaratingly free-revving and brawny power – the five cylinder engines from Audi are legendary.