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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.

Karma Automotive partners with BMW for powertrains

Now in the process of rising from the ashes of Fisker, the newly renamed Karma Automotive has announced a powertrain supply deal with BMW. Only instead of Karma providing BMW with technologies (as Tesla has for Daimler and Toyota), this deal goes the other way around. It is BMW that will be providing Karma with its powertrain components moving forward. Little in the way of specifics was disclosed regarding precisely what the supply deal will entail. However according to the statement below, it will include "high voltage battery charging systems and a wide range of hybrid and EV systems." BMW has demonstrated its competence in developing and manufacturing such components with vehicles like the i3 and i8, and ActiveHybrid versions of the 3 Series, 5 Series, and 7 Series sedans. Karma Automotive is what Chinese component manufacturer Wanxiang renamed the company formerly known as Fisker Automotive once it acquired the rights to the company and the Fisker Karma which it previously produced. The brand name, however, remained the property of Henrik Fisker's coachbuilding operation. The original Fisker Karma was powered by a 2.0-liter turbo four supplied by General Motors, with a lithium-ion battery pack from A123 systems. Karma Automotive Signs Supply Agreement With BMW COSTA MESA, Calif., Nov. 12, 2015 /PRNewswire/ -- Karma Automotive announced today that BMW has agreed to be a supplier in ensuring their vehicles are built with the highest quality automotive parts. BMW will supply Karma Automotive with their latest powertrain components, including high voltage battery charging systems and a wide range of hybrid and EV systems. Throughout automotive history, BMW has been globally recognized for engineering and manufacturing world-class products. They are a proven technology leader and renowned for conceiving and delivering groundbreaking innovations. Karma Automotive will integrate the first BMW components into its plug-in hybrid flagship vehicle, which will re-launch in 2016. The next generation of vehicles already in development will utilize more of BMW's powertrain technology. "The Wanxiang Group is giving Karma Automotive the opportunity to bring a stunning car back to the market, and the partnership with BMW and their outstanding track record is a great fit for the future," said Karma's CEO Tom Corcoran.

Meet the inventor of the BMW 3 Series wagon

It's hard to imagine, but once upon a time, there were only two BMW 3 Series variants: the coupe and sedan. Back before gran coupes, convertibles and yes, even touring models were available, buyers could only get their 3 Series fix if it came with two or four doors and a fixed roof. Back in the mid '80s, BMW engineer Max Reisbock was having some trouble fitting his whole family into his four door. Rather than suck it up and buy a van, he picked up a wrecked 3 Series and got to cutting in a buddy's garage. Months later, he had the very first 3 Series Touring ever built.
At first, he kept the the car to himself, using it to haul friends and family around, but he eventually showed it off to his friends at work. When the BMW executives found out about his project, they called him up to take a closer look. After putting an eyeball on the car, they took it, copied his design, made a few tweaks and quickly rolled out the first production 3 Series Touring. How's that for validation? Check out the video below for Reisbock's story.