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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.

Audi reveals special A5 DTM Champion edition

For this year's DTM touring car championship in Germany, Audi switched (at least in appearance) from the A5 to the more muscular look of the RS5. But now that it's won the title (the driver's title anyway), it's the base A5 that's getting the celebratory treatment.
Limited to just 300 units, the new A5 DTM Champion edition honors its winning driver Mike Rockenfeller in similar fashion to the special-edition BMW M3 that paid tribute to last year's champion, Bruno Spengler. It comes with a rear spoiler, special 20-inch alloys, aluminum trim on the mirror caps and, of course, a smattering of special badges inside and out.
Buyers will be able to place their orders next week in red, white or grey, with any of four engine choices, at a €1,900 premium. That is, in Europe, anyway. Given that DTM hasn't picked up on this side of the Atlantic just yet, we wouldn't go looking for this model at our local Audi dealer Stateside.

2017 Audi A4 First Drive [w/video]

Internally, Audi refers to the A4 lineage with a B designation. Why the discrepancy? The model legacy traces back to the 1972 Audi 80, and the A4 name wasn't adopted until 1996 for the North American market. So the fifth-generation A4 is code-named B9. There is no confusion about what this car means to Audi. In 19 years, the brand has sold more than 12 million A4s around the world, which puts this new generation on the A-list when it comes to brand importance. If you squint, the new car looks like a facelifted version of the last-generation facelift unveiled in 2013. We get the same impression of the new A4 as we do with the third-generation Audi TT: it hasn't been comprehensively reconceived, it's been comprehensively re-detailed. But with a move to the updated VW group platform known as MLB Evo, 90 percent of the components on this car are new. On the outside, those changes are reflected through deeper sculpting on a body that's about the same height as before but 0.5-inches wider, one-inch longer, and with a wheelbase stretched 0.7 inches. The tweaked grille separates reworked Bi-Xenon headlights, which are standard across the lineup now – halogens go bye-bye. LED headlights are optional, as are the matrix units in other markets. Audi claims US-market cars will lose anywhere from 70 to 100 pounds depending on specification. Above those lights is a version of a clamshell hood – its shutline forms the front third of the pronounced shoulder line along the sedan's flanks. Audi designed a new hinge that keeps the hood lined up properly over the life of a car because small misalignments show more easily on the vertical seams. In back there are updated taillights, a standard rearview camera, and a trunk opening that's an even one meter across. In the press presentations, any conversation quickly turns to weight loss and aerodynamic efficiency. The only curb weight we have from Audi so far is for the base sedan, empty and without a driver, with the 1.4 TFSI engine that we don't get, coming in at 2,910 pounds. The current US-spec A4 is listed at 3,583 pounds, and Audi claims US-market cars will lose anywhere from 70 to 100 pounds depending on specification. About 35 pounds of that comes from the chassis, with new forged aluminum links on the suspension, fixed-caliper, four-piston brakes up front, and wheels that are never heavier than 26 pounds. The rest of the weight loss comes from the body, mostly through greater use of aluminum.