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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.

2016 BMW 330e Plug-In Hybrid First Drive

Piecing together the i8 eco sports car taught BMW some valuable lessons, some of which you'll see in the next generation or two of the company's electrified mainstream cars. You won't have to wait that long for BMW to deliver on the key lesson, which can be seen right here in the 330e: make hybrids fun to drive and don't make people compromise on what they like. The 330e neatly sidesteps the traditional character-blanching entry ticket you get with hybrids by delivering almost as much torque as the 340i and a sprint time to 62 miles per hour of 6.1 seconds. For most people eco-conscious enough (especially in a time of cheap gas) to bother with plug-in hybrids, that's going to be quick enough. And so is the 140-mph top speed. It won't quite manage the precision of a normal 3 Series because it's 353 pounds heavier, but it's not far away. This 330e is (theoretically) capable of delivering 25 miles of electric-car range or ridiculous amount of range as a gasoline-electric hybrid. It will post a 44-gram CO2 emissions figure and officially deliver 1.9 liters/100km on the NEDC test cycle in Europe, which translates to 124 miles per gallon equivalent in the US, though it's unclear what the EPA-certified number would actually be. While punching in a straight line is always good, and sipping fuel like it's being rationed is nice, the key part to the 330e is that still handles like a 3 Series should every time you arrive at that one fun corner. It won't quite manage the precision of a normal 3 Series because it's 353 pounds heavier, but it's not far off. BMW has buried the 7.6-kWh lithium-ion battery pack beneath the cargo floor, while the electric motor resides up front, so the weight distribution moves from 50:50 to 49:51, leaving it a touch heavier in the back. Effectively, it's a 3 Series with the 320i's 2.0-liter, four-cylinder gasoline powertrain, the standard eight-speed automatic transmission, and an electric motor sandwiched in between to create a hybrid. The electric motor adds 87 hp to the gas engine's 181 horsepower to offer 248 hp of total power (yes, we know they don't directly add up, but that's the total output). While it has 74 pound-feet of continuous torque, the electric motor can overboost to 184 lb-ft when it needs to. Add that to the gas engine's 214 lb-ft and the car has a maximum of 310 lb-ft – 22 lb-ft shy of the 340i, without pumping out as many emissions.

BMW i3, i8 sales strong enough to reach almost 17,800 in 2014

BMW makes its futuristic i brand vehicles – the i3 and i8 – at a plant in Leipzig, Germany. But the customers most willing to buy one of these plug-in cars live in the country where the lightweight carbon fiber used in the body structure is made: the United States. Speaking at the Detroit Auto Show this week, Ian Robertson, member of the Board of Management at BMW AG, said, "The US is already our largest market for our electric vehicles, the BMW i3 and BMW i8. Worldwide, we sold close to 18,000 BMW i models last year. Nearly three-quarters of these sales occurred in the second half of the year, when the global rollout – including the US – really got underway. Demand for these vehicles continues to be high and I'm delighted that we've been able to increase production to meet that demand." That sounds great, but the numbers aren't huge. BMW sold 6,092 i3s and 555 i8s (for a total of 6,647 i vehicles) in the US last year. Globally, BMW sold over two million vehicles in 2014, and 17,793 of those were plug-in i vehicles (16,052 of the i3 and 1,741 i8s). The production increase wasn't huge. BMW was making just 10 i8 vehicles a day at the beginning, but doubled that to 20 last fall. Since last spring (around April or May), the company has been making over 100 i3s a day, BMW spokesperson Verena Von L'estocq tells AutoblogGreen. Getting production right this first year has meant slow going, but "We're comfortable now," she said, adding that BMW expects more production increases in the future. Related Video: