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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, Mini recall nearly every PHEV model built in 2020 due to fire risk

BMW is recalling a majority of the plug-in hybrid models it built in 2020 because their battery pack poses a fire risk. That's 4,509 vehicles covered by the campaign in the United States, including some made by Mini. The list of cars affected by this voluntary recall includes 2020 and 2021 examples of the 530e, the X3 xDrive30e, and the Mini Countryman SE, coupe and convertible variants of the 2020 i8, as well as the 330e (pictured), the 745Le xDrive, and the X5 xDrive45e from the 2021 model year. All are equipped with a lithium-ion battery pack whose cells might have been contaminated by debris during the manufacturing process, according to a recall notice issued by the National Highway Traffic Safety Administration (NHTSA). BMW hasn't revealed what exactly found its way into the Samsung-built battery pack's cells, or how, but it pointed out the debris can cause a short-circuit, which increases the risk of fires and injuries. It added that it became aware of the problem after four gasoline-electric X5s experienced what it refers to as a thermal incident.  Engineers are currently developing a remedy to the problem. Until a solution is found, BMW is asking owners of affected cars not to charge the battery pack, not to drive in manual mode, not to engage sport mode, and not to use the shift paddles. It expects to begin fixing cars affected by the recall on November 23, 2020. 26,700 cars manufactured between January 20 and September 28, 2020, are part of the recall globally. Outside of the United States, BMW also sells plug-in variants of the X1, the X2, and the 2 Series Active Tourer. It has been a bad month for electrified cars. Ford delayed its Escape PHEV after a recall of its Kuga twin in Europe over fire risk. U.S. safety officials are reviewing reports of fires in the Chevy Bolt EV, and Hyundai has expanded a recall of the Kona EV. Featured Gallery 2021 BMW 330e View 14 Photos Green Recalls BMW MINI Hybrid

2016 BMW X1 First Drive [w/video]

Perhaps more than any other model, the X1 exemplifies the shift going on at BMW. That the X1 is the first front-drive-based car to wear the BMW badge in the US is both remarkable and doesn't matter at all. Some background: The first X1, sold here for the latter half of its six-year run, was an Old BMW. Based on E90 3 Series underpinnings, it was basically a tall, last-gen 3 wagon, a car on short stilts. We loved it. It drove almost exactly like a good 3 Series at a time when that 3 Series was no longer available. It sold in okay numbers. It's gone now. This new X1, the 2016 model, is a sort of about face, or at least a right-hand turn in the engine compartment. This is New BMW. The base engine is again a 2.0-liter four-cylinder, a new design based on the company's modular engine architecture that can spit out threes, fours, and sixes using the same component set. It's mounted transversely, not longitudinally like in the rest of BMW's US offerings. It loses some horsepower to the last X1's 2.0 (228 hp versus 240) and a bit of torque (258 lb-ft down from 260). Again, few will notice. The optional 3.0-liter turbocharged six from the last generation is gone. Not many customers chose it, and the six likely wouldn't fit under the hood of this rearranged X1. EPA fuel-economy numbers match those from the 2015 xDrive28i exactly – 22 mpg city, 32 highway – so no gains there. So packaging won. There's really no other explanation for the longitudinal-transverse swap, except that maybe it's less expensive to build this way. EPA fuel-economy numbers match those from the 2015 xDrive28i exactly – 22 mpg city, 32 highway – so no gains there. But the packaging advantages are abundant. The interior is somewhat narrow, but it's opened up a bit by the lack of a transmission tunnel that would normally eat space between the front occupants. Instead, the center console is set low, with a tall shift lever rising practically from the floor up to meet your hand. There's storage forward of the shifter and a folding center armrest that opens for small items. The original X1 was sold here with rear-wheel as well as all-wheel drive. For obvious reasons, that won't be the case this time around. BMW also won't sell a front-drive model here (although one is offered in Europe and elsewhere) likely because it would involve the admission that this is not your average BMW, but instead a New BMW, one designed for more people and fewer enthusiasts.