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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.

The most efficient gas or hybrid cars of 2024: Not the greenest, but still very green

Not a single electric vehicle appears on the “greener choices” list assembled by the American Council for an Energy-Efficient Economy (ACEEE) in its annual compilation of the most environmentally friendly cars in the United States. But for potential car buyers seeking an efficient, fairly affordable gasoline or hybrid vehicle this year, the list of 12 cars, trucks and SUVs can help with decision making. Topping this yearÂ’s list was the gas/hybrid Honda Accord, priced at $33,990 with an estimated annual fuel cost of $982. Rank Make & Model Powertrain Vehicle Class Green Score MSRP Estimated Annual Fuel Cost* 1 Honda Accord Gas Hybrid Large Car 62 $33,990 $982 2 Kia Niro FE Gas Hybrid Compact SUV 61 $28,315 $885 3 Mitsubishi Mirage Gas Compact Car 59 $17,955 $1,189 4 Lexus ES 300h Gas Hybrid Midsize Car 59 $44,590 $1,073 5 Lexus NX 350h Gas Hybrid Midsize SUV 57 $43,465 $1,207 6 Ford Maverick Gas Hybrid Compact Pickup 55 $24,900 $1,297 7 Toyota Sienna Gas Hybrid Minivan 55 $39,080 $1,304 8 Mini Cooper Convertible Gas Subcompact Car 54 $35,700 $1,412 9 Toyota Highlander Gas Hybrid Large SUV 54 $40,720 $1,348 10 Kia Soul Gas Small Wagon 53 $21,565 $1,467 11 BMW Z4 sDrive30i Gas Two-Seater 50 $53,600 $1,626 12 Mercedes-Benz GLA250 Gas Hybrid Large Van 49 $43,000 $1,596 13 Volvo V90CC B6 Gas Hybrid Midsize Wagon 45 $59,800 $1,843 14 Ford Ranger Gas Standard Pickup 43 $32,670 $1,968 *ACEEE analysis using EIA data of the annual cost of driving 15,000 miles In making its evaluations, the ACEEE examines each 2024 model based on its cost to human health from air pollution associated with vehicle manufacturing and disposal, the production and distribution of fuel or electricity, and vehicle tailpipe emissions. The group also takes into account air pollution associated with EV battery manufacturing. The organization also ranks what it calls the “greenest” cars — it selected the Toyota Prius Prime SE plug-in hybrid is the greenest model of 2024. As well as the “Meanest.Â’Â’ or least efficient vehicle. At the top of that list this year was Mercedes-Benz AMG G63. The group says that the greener choices are those that are available nationwide “with among the lowest environmental impacts in each vehicle class but that didnÂ’t make the Greenest List.

Next-gen BMW 5 Series sedan spotted with production body, possible PHEV

The current BMW 5 Series is just a few years old since its 2009 debut, but the Bavarians are already preparing to put the model out to pasture. Here's our first glimpse at the production bodywork for the next-gen sedan after spotting the wagon version during testing – twice. While the cladding and swirling camouflage make specific details difficult to discern, it doesn't look like we should expect any massive changes in design language from the new model. The nose appears to dip a bit more at the tip of the front end, but otherwise there's no way to mistake this as anything other than a 5 Series. Squint hard enough at the front left fender and you can notice what seems to be a small door. Our spies think that this might be hiding the charging port for a plug-in hybrid version. While the styling doesn't appear to be changing much, the next 5er reportedly has a new platform underneath the skin that supposedly will help it shed around 220 pounds. The debut for this lighter but likely similar looking BMW is expected sometime in 2016.