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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.

Recharge Wrap-up: BMW X5 PHEV debuting in Shanghai, Proterra sets up shop in CA

South Carolina-based Proterra has received funding to build electric buses in California. The California Energy Commission has awarded the company, which is headed by former Tesla executive Ryan Popple, a $3-million grant. Proterra will use the funds for a facility in the LA suburb the City of Industry, where its largest customer, Foothill Transit, also operates. Proterra has also opened an office in San Bruno, just south of San Francisco. Read more at SFGate or at ValueWalk. Despite its "urban mobility" design, the BMW i3 has become popular outside of large cities. Rather than singular urban centers, "The strongholds in this country are parts of California, Texas and southern Florida," said BMW North America CEO Ludwig Willisch. He also says the electric car hasn't been particularly successful in the Northeast, with cities like New York perhaps not being as mindful of sustainability as California. BMW is also nearing i3 sales of 12,000 a year, which Willisch calls "a sustainable rate." Read more at Automotive News. BMW will debut its X5 xDrive40e plug-in hybrid at the Shanghai Motor Show this month. It is the first PHEV from BMW's core brand (not from its i sub-brand). It uses a turbocharged four-cylinder engine and electric motor for a total of 313 horsepower, and a combined fuel economy of about 70 miles per gallon (according to the ECE test cycle). Press days for the Shanghai Motor Show are April 20-21. Read more in the press release below. BMW at Auto Shanghai 2015. At a glance •BMW at the 16th International Automobile & Manufacturing Technology Exhibition (Auto Shanghai) from 22 – 29 April 2015 (Press Days from 20 – 21 April). •BMW presents a world premiere, four Asian premieres and two Chinese premieres in Shanghai. •World premiere: the BMW X5 xDrive40e Sports Activity Vehicle is the first plug-in hybrid series-production model from the BMW core brand. •Asian premiere: the new BMW 2 Series Gran Tourer is the first premium model in its segment to offer maximum variability and room for up to seven people. •Asian premiere: the new edition of the BMW 1 Series is even more expressive, sporting and efficient than before. •Chinese premiere for the three athletes in the luxury class: the new BMW 6 Series Convertible, the new BMW 6 Series Coupe and the new BMW 6 Series Gran Coupe. •Chinese premiere with top-notch driving dynamics, efficiency and exclusivity: the new BMW M6 Coupe and the new BMW M6 Gran Coupe.

BMW offering glitch fix for i3 with range extender

The BMW i3 has received quite a bit of acclaim since its release, with the electric powertrain grabbing a spot on Ward's 10 Best Engines list and the high-tech machine earning the nod as 2015 Green Car of the Year. However, Consumer Reports uncovered a vexing problem with the range-extended version of the hatchback that has plagued it until a recent software update. While CR was driving the range-extended i3 last year, it discovered that when the internal combustion engine was running during low states of charge, hard acceleration could suddenly cut back with no warning to the driver. This was especially problematic when passing. BMW knew about the issue and promised a software update in the spring. That improvement is now available. BMW spokesperson David Buchko tells Autoblog that the software update adds a percent-of-charge indicator to all models of the i3 to let drivers know just how much juice is left. For the range-extended model, it also provides a warning of possible power reduction when the charge reaches two percent. According to Consumer Reports, the revision lets the car anticipate needing more reserve power based on the topography from the navigation system, as well. For any i3 drivers who want the upgrade, they need to visit a dealer for installation, according to Buchko, but it should be come at no cost to owners. Related Video: