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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 next-generation BMW M5 starts here

The next-generation BMW 5 Series hasn't even arrived yet, but BMW is hard at work testing the hottest version of the popular sedan – the sixth-generation M5. Now admittedly, these photos might not look much like an M5. The wheels are big, but not uncommonly so. There's no wild and crazy body kit, or hugely flared wheel arches. But what's that in the back? Are those four exhaust tips? Why yes, yes they are. And take a second look at those wheels. Notice the pizza-pan-sized brakes and huge calipers? Yet another M5 giveaway. But as our spies rightly point out, even though this does represent development work on the next M5, it's a very early prototype. That could also explain the charge port on the driver's side front fender, a feature that we've seen on other 5 Series prototypes. This does not mean the next M5 will be a plug-in hybrid, however. What the next M5 will likely be, though, is all-wheel drive. This isn't a huge surprise, considering that the Mercedes-Benz E63 AMG has already gone AWD, while the Porsche Panamera Turbo and Audi RS6/7 have always had four driven wheels. BMW has even hinted at just such a development, with former M boss Dr. Friedrich Nitschke going as far as saying AWD could arrive on the next M5. "On our cars we are thinking of all-wheel drive, but it won't come before we get the successor of the M5 and M6," Nitschke said in an October 2013 report. "That's the timing and it's not practical to react in the current life cycles." At this point, it's simply too early to guess at when or where the next-generation M5 will debut. We're expecting the next-gen 5 Series at either the 2016 Geneva Motor Show or Auto China 2016 in Beijing. The next M5 could join it, although it's possible it'd get its very own debut at a later date.

2016 BMW 7 Series spied for the first time ever

Ladies and gentlemen, Bimmerphiles and automotive voyeurs of all stripes: here is your next-generation BMW 7 Series. Captured in photographs for the first time ever while doing a spot of cold-weather testing in Sweden, this newly slim 7er will most likely debut at the Frankfurt Motor Show in 2015 and launch in the 2016 model year.
Sources indicate that BMW is targeting a much lighter curb weight for the 7 Series, and will use learnings gained with the i3 and i8 development to add carbon fiber-reinforced plastics in the construction. In return we'd expect the new model - which uses the internal model designation "G11" - to offer improvements in handling, acceleration and fuel economy. As with the current 7 Series lineup, expect the engine range to include turbocharged inline-six engines, one or more V8s and a V12 option.
It's fair to say that, with the car's debut still years down the road, that BMW will work to launch with an impressive suite of in-car technology, too. A completely new version of iDrive shouldn't be ruled out. These shots mark the beginning of a long journey to 2015, and we expect to have loads more information to share in the coming months and years, so stay tuned.