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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 recalling 40k+ motorcycles to replace rear wheel flange

A problem with the rear wheels on a wide array of its motorcycles has prompted BMW and the National Highway Traffic Safety Administration to issue a recall for 43,426 vehicles. In the affected units, the mounting flange on the rear wheel is at risk of cracking if the bolts are over-tightened. If that flange cracks, "the rear wheel may not remain secured to the motorcycle," which is kind of important considering there are only two wheels on a motorcycle to start with. The recall affects certain model-year 1200 and 1300 models – including the R1200GS, R1200RT, R1200GS, R1200R, R1200S, R1200ST, K1200S, K1200R, K1200R Sport, K1200GT, K1300S, K1300R and K1300GT – as well as the HP2 Megamoto, HP2 Enduro and HP2 Sport. Owners of the affects units can expect to head from the manufacturer to arrange having the aluminum flange replaced with a steel one. Related Video: RECALL Subject : Rear Wheel Mounting Flange may Crack Report Receipt Date: MAR 11, 2015 NHTSA Campaign Number: 15V141000 Component(s): WHEELS Potential Number of Units Affected: 43,426 Manufacturer: BMW of North America, LLC SUMMARY: BMW of North America, LLC (BMW) is recalling certain model year 2005-2010 R1200GS and R1200RT, 2006-2010 R1200GS Adventure, 2007-2010 R1200R, 2007 R1200S and K1200R Sport, 2005-2007 R1200ST, 2008-2009 HP2 Megamoto, 2006 HP2 Enduro, 2008-2010 HP2 Sport, 2005-2008 K1200S, 2006-2008 K1200R, K1200GT, 2009-2011 K1300S, 2010-2011 K1300R, and 2009-2010 K1300GT motorcycles. In the affected motorcycles, the rear wheel mounting flange may crack if the rear wheel mounting bolts are over tightened. CONSEQUENCE: If the rear wheel mounting flange cracks, the mounting bolts may loosen and the rear wheel may not remain secured to the motorcycle, causing a loss of stability and increasing the risk of a crash. REMEDY: BMW will notify owners, and dealers will replace the existing aluminum rear wheel flange with a steel one, free of charge. The recall is expected to begin April 21, 2015. Owners may contact BMW customer service at 1-800-525-7417. NOTES: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov. Featured Gallery BMW HP2 Sport View 13 Photos News Source: National Highway Traffic Safety AdministrationImage Credit: BMW Recalls BMW Motorcycle bmw motorrad

BMW reveals X4 M40i performance crossover

The first details and images of the new BMW X4 M40i leaked out Tuesday, and now the Bavarian automaker has released all of the information on its new performance crossover. The latest model in BMW's M Performance line offers an array of upgrades over the existing X4, and they start under the hood. That's where Munich fitted a new 3.0-liter turbocharged inline six based on the one found in the X4 xDrive35i (whose place this model takes at the top of the X4 lineup). The engine is tuned to deliver 355 horsepower and 343 pound-feet of torque. In addition to the twin-scroll turbocharger, the engine also boasts variable cams and valves, as well as a high-precision injection system. This translates to a 0-60 time of 4.7 seconds – a figure which BMW cites as "best-in-class." Power is channeled to all four corners through an eight-speed automatic transmission and a re-calibrated xDrive system that's biased to the rear wheels. Naturally the suspension has been upgraded as well, with increased camber, stiffer springs, reinforced stabilizers front and rear, and active dampers. The steering rack has also been retuned. You'll be able to tell the M40i model from lesser X4s by its enhanced appearance. Though the aero kit looks largely the same as the stock version, BMW has fitted the M Performance model with metallic accents, 19- (or available 20-) inch alloys wearing Michelin Pilot Super Sport rubber, and a variable sport exhaust. Inside, it's also upgraded with a unique steering wheel, shifter, sports seats, and specific badging. This adds up to a crossover that may not be a full-on M model, but promises up the performance quotient significantly over the rest of the X4 line. THE NEW BMW X4 M40i - World premiere of the new inline 6 cylinder TwinPower Turbo engine. - Intelligent BMW xDrive: four-wheel drive with rear-wheel-drive characteristics. - A sporty chassis specifically tuned to M Performance specifications. Woodcliff Lake, N.J.- September 30, 2015... Today, with the introduction of the new BMW X4 M40i, the successful BMW X4 has gained a new top model. In the Sports Activity Coupe segment (SAC), the BMW X4 M40i is setting new standards with enhanced driving dynamics and best-in-segment acceleration. The new BMW X4 M40i will be available at dealers starting February 2016. Design. The exterior of the new BMW X4 M40i makes it stand out as a clear member of the BMW M Performance family.