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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

AC Schnitzer packs 400-hp, tri-turbo diesel into 1 Series

At first blush, this might look like your run-of-the-mill BMW 1 Series, maybe with a few modifications. What you're actually looking at is a monster hot hatch with 400 horsepower and 590 lb-ft of torque. From a diesel. For this year's Essen Motor Show – Germany's equivalent to SEMA – the Bimmer specialists at AC Schnitzer prepared the ACS1 5.0d concept you see here. Its selling point (if only it were for sale) is the combination of BMW's most powerful diesel engine and its smallest model. It utilizes the 3.0-liter triple-turbocharged inline-six diesel engine from the M50d versions of the 5 Series, X5, and X6 sold in Europe. That engine is normally rated at 376 hp and 545 lb-ft, which is already a ton of muscle. But Schnitzer has bumped up the output on both counts, and slotted it into a 1 Series hatchback. The result is a 0-62 time of just 4.5 seconds, leaving the M135i and M235i in a cloud of diesel soot. Of course, Schnitzer has plenty more to showcase at Essen this year, including modifications for the 3 Series, X6 M, and Mini JCW. And you can bet all the other major European tuners will be on hand at the expo to show their wares, too. But as far as outlandish creations go, this monster diesel hot hatch is what's caught our attention. Compact and incredibly powerful The 1-series by AC Schnitzer with impressive motorsport quality At first sight, you do not expect brute force from the BMW 1-series. So the performance of the compact Bavarian after the AC Schnitzer tuning experts have equipped it with the M50d power plant and impressive performance upgrade, is even more incredible. Originally designed for the 5-series, the "Diesel M-Technik" pack propels the 1-series a long way forward. The smallest BMW series now has an impressive drive concept from AC Schnitzer. After the performance upgrade, the concept engine of the ACS1 5.0d delivers 294 kW/400 hp and 800 Nm torque for generous thrust. Equipped in this way, it takes just 4.5 seconds to sprint from 0-100 km/h. The acceleration from 80-180 km/h is even more impressive: the ACS1 5.0d takes just 7.9 second for this. The smallest of the compacts, the 114i, is already impressive thanks to a power increase by 52 hp to 154 hp. The four-cylinder petrol engine of the 116i, thanks to motorsport technology, now delivers 204 hp instead of 136 hp. The same figure is also achieved by the 118i, which previously had 170 horses under the bonnet.