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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.

BMW X4 Concept images leak ahead of Shanghai debut

Last month, BMW confirmed that its long-awaited X4 crossover would debut next year, but other than imagining a smaller X6-shaped crossover, we really had no idea what the new niche model would look like. That is until a Russian website, Autowp, leaked a handful of embargoed images this morning showing the X4 Concept that will be unveiled in a couple of weeks at the Shanghai Motor Show.
From what we can see of this concept's styling, there are more elements shared with current BMW models than not. The face of the concept is an attractive blend of the current 3 Series sedan and the X3, while the roofline has definitely plucked right from the X6. This thinly veiled concept should carry over almost untouched when it enters production with the exception of the door handles and the overly stylized fascias and side mirrors. According to CarScoops, it will measure the same length as the current X3 and use the same engine lineup as well. Stay tuned, as we'll have more information on this concept shortly.

BMW i3 misses top Euro safety rating [w/videos]

The Euro NCAP just tested a recent batch of new cars including the 2014 BMW i3, and the EV Bimmer scored less-than-perfect results. Though not horrible, BMW's all-electric/range-extended i3 was given a four-star (out of five possible) crash rating due to concerns with front-occupant whiplash and side-impact protection.
Based on the crash results, the BMW provided suitable protection for occupants in the frontal, side barrier, pedestrian and child-seat tests, but the i3 was tripped up when it came to the more severe side pole test and the rear-impact test. The pole test showed protection to the chest of the test dummy was "weak," and the front seats only provided "marginal" protection against whiplash for front passengers. Scroll down to watch two videos released by the Euro NCAP of the i3 being tested.