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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.

2013 Audi S3

Coming Soon To Our Shores With Two More Doors And A Trunk
The Audi S3 is not exactly a sales juggernaut, despite it being a bit of a legend for passionate fans of the small German premium genre. In most markets outside of Europe, people may consider such setups as the S3 three-door tested here, look at the price, and then think maybe they should just get a nice A4 sedan with greater practicality for similar cash. That certainly has been one reason Audi has never officially brought the S3 hatchback to the United States. And the 335-horsepower RS3 Sportback? Forget about it nearly everywhere but in Germanic regions, Switzerland and the UK.
All of which automatically turns the new S3 hatchback into an unattainable object of desire for many fans of the four-ringed brand. The good news, of course, for many markets not on the three-door or S3's dance card is that most of us will get a shot at buying the new S3 sedan that will be powered by the same drivetrain tested here. We reported heavily on the sedan version from the recent New York Auto Show and are convinced that there is much for North American shoppers to like.

2015 Audi A3 Sportback E-Tron

A little more than a year ago, I drove an Audi A3 E-Tron prototype - an early concept electric vehicle built on the outgoing second-generation A3 platform. While I was impressed with the technology, its 3,800-pound weight, 10-second 0-60 time and 90-mile range will likely put it only mid-pack, at best, among its future competitive set. But Audi promised bigger and better things would come.
I didn't have to wait long. Immediately following the Los Angeles Auto Show, Audi asked me come drive its all-new successor built on the company's third-generation A3 chassis. Compared to last year's model, the new plug-in hybrid electric vehicle (PHEV) boasts a lighter curb weight, quicker acceleration and six times the range. Calling it improved is an understatement. Best of all, it's heading to production.
Technically speaking, the 2015 Audi A3 Sportback E-Tron is a parallel hybrid, meaning its electric motor is sandwiched between a combustion engine and an automatic transmission - either, or both, is capable of powering the front wheels. The gasoline-powered engine is a direct-injected and turbocharged 1.4-liter four-cylinder, rated at 150 horsepower. The transmission is a six-speed dual-clutch gearbox. A 75-kW electric motor sits between the two. Water is used to cool the gasoline engine, the electric motor and the battery pack - there are three independent closed loops.