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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 to offer carbon fiber wheels in a year or two

The Citroën SM sat on the first set of production glass fiber and resin wheels in 1972 when parent company Michelin developed the exotic hoops in order to take the SM rallying. It wasn't until 2008 that we got the first all-carbon-fiber wheel for passenger cars in the form of a prototype model from Weds Sports in Japan that remained a prototype. Australian company Carbon Revolution followed that a year later with its CR-9 all-CF wheel, first introduced on the Shelby Ultimate Aero and now available for independent purchase for about $15,000 per set. BMW could be the first OEM to offer entire wheels in carbon fiber reinforced plastic in two years.
The wheels - either all-CFRP or using a CFRP rim and alloy spokes - were shown off during BMW's Innovation Days in Munich and are products of the development work done on its i-branded cars. The full-CFRP wheel is 35-percent lighter than a forged alloy wheel, the hybrid alloy and CFRP wheel is 25-percent lighter, making for a decent drop in unsprung rotating weight. As demonstrators during a tech day the wheels aren't yet in the pipeline for production and EU approval, but an article in Auto Express claims that they could be on the market as soon as two years from now.
Other possible parts include a full carbon fiber steering wheel and propeller shaft, the latter of which is coming as a single-piece component on the new M3 and M4. BMW is also talking up its use of secondary carbon fiber - waste material from i3 and i8 production - that can be used for items like IP support structures, seat frames and spare wheels in place of traditional metals like aluminum and magnesium. There's an excerpt of the Innovation Day press release below with more details.

Next BMW 6 Series, M6 to take aim at Porsche

Since BMW reintroduced the 6 Series line back in 2003, the big two-door has happily sat as the brand's de facto grand tourer. That will allegedly change come 2017, as Car is reporting that Munich will put its coupe on a diet with the so-called G15 generation, allowing the 6 to go after the likes of Porsche. All three of the current 6's body styles will be carried over for 2017, with the base 640i Coupe trimming over 500 pounds of body fat, to around 3,450 pounds. Even the droptop is getting some lipo, dropping from 4,255 to around 3,750 pounds. It's unclear how much the Gran Coupe will be lightened, as it will be the only member of the 6 Series family that's growing in size. BMW will stretch the wheelbase of its fullsize, four-door coupe, which should make it decidedly more sedan like. The weight savings come thanks to a new modular architecture that promises a "more advanced material mix." That means carbon fiber, high-strength steel and aluminum elements, and even some titanium and magnesium bits. Along with xDrive all-wheel drive, Car is promising new six- and eight-cylinder engines, with the 640i's 3.0-liter, turbocharged gas engine producing 347 horsepower while the diesel mill turns out 333. The 4.4-liter V8 of the 650i will deliver 476 ponies, while the range-topping M6's twin-turbo V8 will reach the magical 600-hp figure. Of course, we can expect to hear more about the next 6 in the coming months and years. In the meantime, though, let us know what you think of Car's positing below, in Comments.