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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 rolls out new M4 safety car for DTM

Ever since revealing the M4 on nearly five months ago, BMW has been hard at work getting its new muscle coupe out on the track. It's made a touring-car version to compete in DTM and a safety car to set the pace at MotoGP races, and now it's combined both into a new safety car for DTM as well.
The ninth M4 on the DTM grid is based on the production version, but fitted with numerous upgrades over the course of a two-month conversion process. For starters, it's been equipped with nearly exterior component from the M Performance Parts catalog, including the quad-tipped exhaust, front splitter, rear spoiler and diffuser, blacked-out grille, special mirror caps, side sills... the works. But that's not the end of the story.
BMW M GmbH also gutted the interior, removing the rear bench and replacing it with a roll cage. It's got a pair of Recaro racing buckets with Schroth harnesses, plus special LED emergency lighting, radio communication system and, of course, special livery (albeit nowhere near as cool as the MotoGP one) to distinguish it as the official safety car when it makes its debut at the Nürburgring on August 17.

BMW recalling 1 Series ActiveE over bad drivetrain housing

There are always growing pains when automakers introduce new technologies. BMW is learning this with the electric powetrain used on the 2011 BMW ActiveE. According to the National Highway Traffic Safety Administration, about half of the all-electric 1 Series coupes currently in the hands of the public are being recalled for a potential problem that could leave the cars stranded.
With 700 ActiveE models running around the US, 360 of these cars have insufficient sealing between the electric motor and transmission, which could lead to premature wear to the connection between the two, which in turn could result in a loss of propulsion. BMW started notifying affected owners by phone earlier this month.
While no automaker wants a recall on its hands, it's much better for BMW to learn such a lesson now on the low-production, lease-only ActiveE ahead of the car's successor, the BMW i3, which is expected to be a much higher-volume EV. Scroll down for the official recall notification.