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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 NA president says i3 beats Tesla EVs thanks to lighter all-around footprint

Those waiting for a full-out brawl between Tesla Motors head Elon Musk and BMW North America chief Ludwig Willisch will have to wait a bit. For the bloodthirsty, there are signs of some healthy competition and a little bit of green-car sniping between the two automakers. Willisch, speaking at the Detroit Auto Show earlier this month and responding to questions about Tesla, noted (without mentioning that company by name) that the production process of the German automaker's i3 plug-in was "greener" than any other. According to Business Insider, Willisch highlighted the fully recyclable materials used to construct the i3 as well as the hydropower used at the carbon fiber plant in Moses Lake, WA. Willisch also noted that the Tesla Model S is "very heavy on the braking. Our car feels just like a normal car. That's a big difference when it comes to driving," Automotive News said in a separate report. The latter model weighs about a third less than the Tesla, though it also has an EV range about a third as big. The BMW executive did allow that the Tesla did make a good proverbial "snowplow," not for its driving characteristics but for its ability to get more people conformable with electric vehicle technology. Musk was asked about the i3 in an August conference call and laughed before noting that the i3 had "room to improve." No word on whether Musk and Willisch will be sending each other Valentine's Day cards next month.

BMW looking to fix i3 acceleration problem uncovered by Consumer Reports

The BMW i3 has been hailed in some quarters as the future of electric mobility, what with its innovative carbon-fiber-reinforced plastic body and commitment to sustainable materials wherever possible. The modernist little hatch is even available with a 650cc two-cylinder gas engine with 34 horsepower to act as a range-extender for those who want it. However, that optional engine might have a drawback - at least for the moment.
Consumer Reports brought the problem to light when one of its drivers was behind the wheel of an i3 using the range-extender. When the driver attempted to pass another vehicle on a rolling, two-lane road, the BMW suddenly had no power to accelerate - a scary situation. CR started examining the car and found something pretty shocking: After driving at a constant speed for a while without any regenerative braking in range-extended mode, acceleration to 60 miles per hour plummeted from about 9 seconds normally to a staggering 27 to 40 seconds in their testing.
A BMW spokesperson told CR that it knows about the problem and has a fix coming next spring that also works on current models. The upgrade includes a state of charge indicator, a warning about loss of power and uses the car's navigation to boost the battery before driving on rolling terrain. It is not clear if the severe power deficiency will also eventually result in a recall.