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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.

New BMW i3-like Visio.M EV concept uses lightweight resin

It's not a new version of the BMW i3, but an updated version of a lightweight concept car from SABIC, BMW, the Technical University of Munich, Daimler and others does bear a certain resemblance to the well-designed plug-in city car. From the black "glass" in the hatch to the angled line tail lights to the up-and-down window line, you can see a sort of family resemblance (see an i3 comparison photo here). And, of course, they both have an electric powertrain. But the changes made to the new lightweight urban electric concept vehicle is more of an exercise in what's possible rather than a way to evolve the i3 and i8 into a broader i family of vehicles. Even so, what we see here is interesting, since SABIC found all sorts of new ways to take weight out of the car as part of the Visio.M (Visionary Mobility) project, which was first announced in 2012. Let's start with the window material, which as you might guess from the quotation marks above, is not made of glass but is instead SABIC's Lexan polycarbonate (PC) resin plastic. The lower weight (the PC helps shed about 29 pounds) adds two miles of range while the PC resin has better thermal conductivity compared to glass and so does even more because the HVAC system can be more efficient. According to SABIC's computational fluid dynamics analysis, an extra 9-10 miles of range, in fact. Without the battery, this concept weighs just 992 pounds. Remember, BMW already made a lot of weight-reduction measures in the i3 thanks to carbon fiber reinforced plastic, so to make the "glass" lighter would only help boost efficiencies on a production vehicle that uses a resin like this. Read more below. SABIC's LEXAN™ resin delivers weight savings and thermal efficiency for new ultra-lightweight electric car concept developed by BMW-led Visio.M Consortium Munich, October 20, 2014 Today, at the Technical University of Munich (TUM), BMW, Daimler, TUM scientists and a consortium of industry participants showcased a lightweight urban electric concept vehicle with various advances, including an all-plastic design of the car's windows. The windows are made of LEXAN resin, a polycarbonate (PC) material, and coating technologies from SABIC, a leading developer of PC glazing for automotive windows and many other thermoplastic solutions for the automotive industry.

Acura NSX, a pair of 2 Series Gran Coupes and a time machine | Autoblog Podcast #628

In this week's Autoblog Podcast, Editor-in-Chief Greg Migliore is joined by West Coast Editor James Riswick and Road Test Editor Zac Palmer. This week, they're driving a 2020 Acura NSX, two versions of the BMW 2 Series Gran Coupe (M235i and 228i) and the updated 2020 Honda Civic Si. Then, the gang gets to talking about what they'd drive in 1975 and 1985, along with plenty of other tangents. Finally, they wrap it up with news about the upcoming 2021 Acura TLX Type S and the fate of this year's Woodward Dream Cruise. Autoblog Podcast #628 Get The Podcast iTunes – Subscribe to the Autoblog Podcast in iTunes RSS – Add the Autoblog Podcast feed to your RSS aggregator MP3 – Download the MP3 directly Rundown Cars we're driving 2020 Acura NSX 2020 BMW 2 Series Gran Coupe (M235i and 228i) 2020 Honda Civic Si Cars we'd buy if it were 1985, and 1975 2021 Acura TLX to revive Type S Is the Woodward Dream Cruise canceled? Feedback Email – Podcast@Autoblog.com Review the show on iTunes Related Video: