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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.

2016 BMW 330e Plug-In Hybrid First Drive

Piecing together the i8 eco sports car taught BMW some valuable lessons, some of which you'll see in the next generation or two of the company's electrified mainstream cars. You won't have to wait that long for BMW to deliver on the key lesson, which can be seen right here in the 330e: make hybrids fun to drive and don't make people compromise on what they like. The 330e neatly sidesteps the traditional character-blanching entry ticket you get with hybrids by delivering almost as much torque as the 340i and a sprint time to 62 miles per hour of 6.1 seconds. For most people eco-conscious enough (especially in a time of cheap gas) to bother with plug-in hybrids, that's going to be quick enough. And so is the 140-mph top speed. It won't quite manage the precision of a normal 3 Series because it's 353 pounds heavier, but it's not far away. This 330e is (theoretically) capable of delivering 25 miles of electric-car range or ridiculous amount of range as a gasoline-electric hybrid. It will post a 44-gram CO2 emissions figure and officially deliver 1.9 liters/100km on the NEDC test cycle in Europe, which translates to 124 miles per gallon equivalent in the US, though it's unclear what the EPA-certified number would actually be. While punching in a straight line is always good, and sipping fuel like it's being rationed is nice, the key part to the 330e is that still handles like a 3 Series should every time you arrive at that one fun corner. It won't quite manage the precision of a normal 3 Series because it's 353 pounds heavier, but it's not far off. BMW has buried the 7.6-kWh lithium-ion battery pack beneath the cargo floor, while the electric motor resides up front, so the weight distribution moves from 50:50 to 49:51, leaving it a touch heavier in the back. Effectively, it's a 3 Series with the 320i's 2.0-liter, four-cylinder gasoline powertrain, the standard eight-speed automatic transmission, and an electric motor sandwiched in between to create a hybrid. The electric motor adds 87 hp to the gas engine's 181 horsepower to offer 248 hp of total power (yes, we know they don't directly add up, but that's the total output). While it has 74 pound-feet of continuous torque, the electric motor can overboost to 184 lb-ft when it needs to. Add that to the gas engine's 214 lb-ft and the car has a maximum of 310 lb-ft – 22 lb-ft shy of the 340i, without pumping out as many emissions.

BMW's fuel cell coming after 2020

Honda made news earlier this week at the Tokyo Motor Show by announcing details of the what will be its first production hydrogen fuel cell vehicle earmarked for the US next year. As for BMW? Not so fast. The German automaker might start working on a fuel cell vehicle for one of its larger sedan lines, but don't expect it to see the light of day before 2020, Reuters reports, citing remarks made by BMW executive Merten Jung in Tokyo. Bimmer has been collaborating with Toyota on advancing fuel-cell technology since 2013, but any production vehicle from BMW would take place after that collaboration expires. In fact, one point Jung made was that the BMW fuel cell would be able to go further on a full tank (of hydrogen) than the Toyota Mirai's 300+ miles. Earlier this year, reports surfaced that BMW may have a fuel-cell vehicle ready before the end of the decade, and that it would likely be sold under Bimmer's i brand of advanced-powertrain vehicles. Additionally, this summer, videos started coming out showing a hydrogen fuel cell i8 prototype (a rather sporty one, actually) as well as a 5-series prototype, so getting a handle on BMW's plans for fuel cell vehicles is a bit of a moving target. As for Honda, the Clarity will be earmarked for fleet and business customers in Japan first before marketing starts for everyday drivers. We've got some brief first-hand impressions of what it's like to drive a Clarity prototype here.