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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 and Jaguar Land Rover recalls address seatbelt issues

Audi and Jaguar Land Rover are each recalling several thousand vehicles for separate potential seatbelt issues. The recalls cover the 2022 Audi A3 and S3; 2022 Jaguar F-Type, F-Pace and XF; and the 2022-23 Land Rover Defender, Discovery, Discovery Sport, Range Rover Sport and Range Rover Velar. Examples of these vehicles may have shipped with seatbelt pretensioners that will not function properly in the event of an accident.  Audi is recalling its sedans for tensioner devices that may not adequately restrain drivers or passengers during a crash. The issue was discovered during Korean market crash testing of the high-performance RS 3.  "The seat belt tensioner in the affected vehicles serve the purpose of holding the passenger in his position in the seat," Audi said in its defect report to NHTSA. "In the event of a crash, the retention force of the seat belt may not reach the intended level. As a result, the position of the body can be further to the front of the seat, which leads to a negative influence on the whole restraint system, increasing the risk of injury." A different company, Jaguar Land Rover (JLR), meanwhile, also has an issue with a batch of pretensioners installed in its cars and SUVs. Pretensioners are the devices that fire off to rapidly retract the seatbelt when a crash is detected. Most utilize an explosive charge and pressure tube JLR says that some pretensioner devices provided by one of its suppliers may not have properly-specified pressure tubes that may not channel the gasses to the retraction mechanism correctly.  "A damaged front seat belt pretensioner tube may have been installed on the seat belt retractor," JLR's report said. "This may result in a reduced level or complete loss of pre-tensioning in the event of a crash and increased occupant injury." Owners of the models included in both recall campaigns should receive notices from the manufacturers in the coming months.  Related video: Recalls Audi Jaguar Land Rover Ownership Safety SUV Sedan

Audi: 20-25% of our cars will have a plug by 2025

If you like the promise of Audi's E-Tron Quattro concept, you're going to love this post. Speaking at an intimate dinner in Los Angeles the night before the start of the Los Angeles Auto Show, Audi of America president Scott Keogh had nothing but positive things to say about his brand's future plug-in vehicles, including the production version of the E-Tron Quattro. The most interesting was that he said he expects a full 20 to 25 percent of Audi's sales to be electrified by around 2025, and there was lots of detail to back up his vision. "This is the reality as we see it." - Scott Keogh Keogh wasn't making specific predictions, but it's been a long while since we've heard such a high-level Audi executive act like such a troubadour for the electric vehicle future. As long-time readers will remember, we used to hear things like this from Nissan's Carlos Ghosn, but public predictions have taken a bit of a back seat recently. It's promising to hear reasonable optimism again. "When you look at what needs to happen and you look at what we see happening in the marketplace, we're probably looking at a world where 25 percent of Audi's sales, over the next ten years, just to throw out a rough point in the future, are either going to be full electric or have some plug," Keogh said. "This is the reality as we see it." The reason Keogh is so positive is because Audi thinks the E-Tron Quattro concept is going to birth one heck of an EV. Whatever it's called when it arrives – it's unlikely to be the Q6, as some rumors have it. Internally, Audi is calling it the C-BEV, since it is a C-segment Battery Electric Vehicle – the concept previews a luxury all-electric vehicle with a range of over 300 miles. No one is talking about the price yet, but Audi of America's director of product management, Filip Brabec, did say that the sweet spot for the pricing is in the range of how mainstream luxury vehicles are priced today. "If you can put a car in the market that's priced right ... people are going to want to buy it," Keogh said. Read into all of that what you will. It's not just the price that's going to be right. Keogh said that the key point is changing hearts and minds to want electric vehicles. That means tripling down on public infrastructure (see more below) and making sure the car itself is amazing. "Everyone knows, in the history of the world, launch a defining, game-changing product, in whatever category it bloody is, and - boom - the world changes," Keogh said.