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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 says SUVs killed the sports car market

In many ways, we're living in a golden age of automotive performance. After all, it's possible to show up at a Dodge dealer, hand over about $60,000 and storm away with a 707-horsepower Challenger Hellcat. Or for those who prefer a touch more luxury, the BMW M4, Mercedes-AMG C63 and latest Cadillac ATS-V offer between 425 and 503 horsepower, depending on your pick, with a bit more poshness. However, none of these powerful vehicles fit the classic definition of a two-place, droptop sports car, and according BMW head of sales Ian Robertson, that's because the segment is very much in the doldrums.
According to Robertson, two factors seriously wounded the classic sports car market. First, the global economic crisis of a few years ago put a serious hurt on sales, according to Bloomberg. Further worsening the situation, the boom in popularity of luxury SUVs and crossovers in the past few years hasn't allowed for much recovery. Even car-hungry China hasn't helped much because of the smog in many cities and preference among some of the very rich there to be chauffeured.
Combined, Audi TT, BMW Z4 and Mercedes-Benz SLK sales peaked around 114,000 units a year in 2007, but they are only expected to reach 72,000 annually by the end of the decade. Robertson is pretty pessimistic about the market's comeback too. "Post-2008, it just collapsed. I'm not so sure it'll ever fully recover," he said to Bloomberg.

Audi is working on a suspension that gets power from bumpy roads

Regenerative brakes aren't new. They're on virtually every hybrid and EV, and they're even starting to pop up on traditional gas-powered cars, like with the i-ELOOP-equipped Mazda6. But even with these systems, cars can get more efficient, and Audi thinks it found yet another source of wasted energy. The source? The suspension. The idea is to turn the kinetic energy that goes into the dampers into usable energy instead of as waste heat. Audi isn't the first auto company to come up with regenerative suspension – nearly three years ago, ZF introduced its GenShock technology, which used a valve attached to traditional, oil-filled hydraulic shocks to recapture kinetic energy from movement caused by bumps in the road. Audi's prototype technology, which it calls eROT, replaces traditional dampers with horizontally oriented electromechanical rotary dampers. eROT is apparently short for electromechanical rotary damper. Neat. In testing, eROT recovered an average of 100 to 150 watts on a typical German road, three watts from a fresh piece of pavement, and 613 watts on a rough stretch of tarmac (wattage is calculated as power over time, so this is actually the rate at which the system harvests energy). The dampers channel that energy to a tiny, 0.5-kWh, 48-volt battery. The prototype is claimed to cut CO2 emissions by three grams per kilometer (4.8 grams per mile), while the company believes a future production version could save up to 0.7 liters of fuel per 100 kilometers of driving. Converting the savings to American miles per gallon isn't easy, so we'll use a practical example. In the US, the Q7's supercharged 3.0-liter V6 returns a combined rating of 21 miles per gallon, which works out to 11.2 liters per 100 kilometers. Apply eROT's 0.7L/100km savings, and the Q7's economy would improve to 10.5L/100km, or 22.4 mpg, a 1.4-mpg improvement. That's not huge, but because math, 0.7L/100km is more dramatic on a more fuel efficient vehicle – taking an A3's 27-mpg combined rating and adding eROT would drive efficiency up 2.4 mpg, for example. There are a few other big benefits beyond fuel and emissions savings – Audi claims eROT provides a more comfortable ride than traditional active suspensions, because engineers can tune the compression and rebound strokes independently of each other. Beyond that, the horizontally oriented rear suspension geometry means more cargo space, since the dampers don't poke up into the cabin like they normally do.