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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.

Recharge Wrap-up: Renault's electric motors, BMW i3 is AM free

Why isn't AM radio offered in the BMW i3? Some drivers – particularly those interested in local traffic reports – have noticed its absence. BMW says that the electromagnetic interference from the electric drivetrain caused poor performance, and that while reception wasn't always terrible, it wasn't up to their standards. Rather than have customers complain to their dealers, who would be unable to do anything for them, BMW has disabled AM reception in the i3. Some customers have hacked their cars in order to enable the AM radio, despite possible warranty issues, and have found the reception to be acceptable. Read more at Green Car Reports. Saab's current parent company, National Electric Vehicle Sweden (NEVS), broke ground for production and R&D facilities in Tianjin, China. The facilities are part of joint ventures with the city of Tianjin and State Research Information Technology (SRIT). In addition to investments of over $190 million from SRIT and Teamsun, NEVS has received $1.6 billion in credit from the Bank of China to develop its business there. The new Tianjin factory will have a capacity of 200,000 new energy vehicles per year. The facility in Trollhattan, Sweden will provide manufacturing planning, training, and product supply for the Tianjin plant. Read more at Green Car Congress, and in the press release from NEVS. Renault is building the new R240 electric motor for the Zoe at its Cleon plant. The plant and its employees, which specialize in the Energy dCi diesel engine, have adapted to produce high volumes of the electric motor as well, including a 6,000 hours of training for the staff and millions of dollars in investments. "We aim to become the leading powertrain plant for the Alliance," says Cleon plant director Mendi Ammad. The plant is capable of producing 50,000 units of the R240 motor per year, with that number expected to double in the future. Read more about the plant and the production process the press release below. NEW ELECTRIC MOTOR STRENGTHENS POWERTRAIN EXPERTISE AT CLEON ZOE's new electric motor, unveiled at the Geneva Motor Show, is a 100% Renault motor manufactured at the French site of Cleon, already specialized in highly technical powertrain production. Until now, the flagship of the Cleon plant was the Energy dCi (130, 140, 160) internal-combustion engine. The diesel unit with advanced technological content has made a name for itself at Groupe Renault, the Alliance and with our partners.

Next BMW X5 caught testing in the snow

That's not taken long at all. Less than three years after BMW introduced the current X5, the German automaker has already kicked off winter testing for its replacement. The new Sport Activity Vehicle (that's BMW for crossover) has been spotted in snowy terrain, complete with heavy camouflage and extra driving lamps. Now, this is a mule, which means we're absolutely not looking at production sheetmetal. Instead, we'd wager the next X5 is hiding well beneath this swirly camouflage. Compared with images of the current car, it looks like we're seeing a longer front overhang, a shorter rear overhang, and a tighter dash-to-axle ratio. That makes us think the next X5's exterior dimensions might be just a smidge smaller than the current model. And that gels with at least some of what our spies are telling us. For one, they're reporting that the new X5 will be significantly lighter, as is the trend nowadays. It will also be more comfortable and techy, both of which would put it in line with the new 7 Series. Beyond that, though, we're in the very earliest days of BMW's next SAV. The debut of the fourth-generation X5 will likely come in 2018 as a 2019 model. Related Video: