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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.

Audi SQ7 spied for the first time

Audi isn't really hiding that its engineers are hard at work on a high-performance version of the latest Q7. However, we haven't seen any of the fruits of this labor, until we got these fresh spy shots of the SQ7. With seemingly no camouflage on the car, these photos might give a very good idea of what to expect from Audi's speedy SUV. One big tip-off of the model's performance aspirations is the redesign of the front end's lower portion. New ducts beside the foglights send cool air to what appear to be intercoolers. This test model rides on a very cool-looking set of basket-weave style wheels, and the big, cross-drilled brakes are easy to spot behind them. At the rear, the quad exhaust tips also signal something special. Our spies also snapped some shots of the interior. If there is any question about whether this is the SQ7, these photos certainly assuage it. The badging is plain as day on the gauges, but at this point the changes appear to be fairly minimal beyond that. We know the SQ7 is going to get more power, but the method isn't officially confirmed yet. Although, Audi technical boss Dr. Ulrich Hackenberg said bluntly last year that it would use an electrically turbocharged engine, possibly an evolution of the V6 diesel in the RS5 TDI Concept. Hackenberg also suggested that the SQ7 would go on sale in 2016. Though, the actual debut might come earlier. Regardless, the tweaks should make the SUV quite a performer. Even on the standard version, it weighs 700 pounds less than the previous generation, while remaining about the same size.

Audi reveals even more efficient 2015 R18 E-Tron Quattro

We've seen two of this year's LMP1 manufacturer challengers – Porsche's updated 919 Hybrid and Nissan's GT-R LM Nismo. Audi has finished cooking up the successor to its Le Mans champion and unveiled the fifth-generation R18 E-Tron Quattro, even better than before. The bodywork monocoque is carried over, but the body around it has been reshaped to improve airflow from front to rear with a new hood, front fenders and wheel arches, and radiator configuration. The engine cover behind the cockpit is shrunk more closely around the engine, and there are new headlights. The hybrid system can expend double the energy per lap this year, putting Audi in the four-megajoule class under the energy-use regulations. That extra energy will come from 17-percent more capacity built into the flywheel storage system and an electric motor good for 272 horsepower. The revisions haven't increased the weight of the car, pegged to the minimum allowed at 870 kilograms. They have, however, forced changes to the TDI engine, which has to use 2.5-percent less fuel per lap to offset the increased hybrid output. The 558-hp V6 has been optimized such that it "managed to more than compensate for the loss" of fuel allowed, and Audi expects "significantly" lower lap times this year and less fuel used. We're still waiting to see what Toyota has done to its World Endurance Championship-winning racer, but we're already looking forward to this year's Le Mans. It's going to be cracking. You'll find a press release below the videos with more info on the Audi. Related Video: New Audi R18 e-tron quattro even more efficient - Aerodynamics, hybrid drive and many other details improved - Efficient TDI engine consumes even less fuel than before - Technologies from Le Mans winning cars now in production at Audi Ingolstadt, March 21, 2015 – Audi is starting the 2015 season with a thoroughly revised R18 e-tron quattro. In the FIA World Endurance Championship (WEC) and in the Le Mans 24 Hours as the season's pinnacle event, Audi is going to compete with a hybrid sports car in the 4-megajoule class. A twofold quantity of hybrid energy, fundamentally revised aerodynamics, the next step in lightweight design and a lot of detailed work characterize the fifth generation of the Audi R18. "The possibilities of the revolutionary regulations that have been in effect for LMP sports cars since 2014 are far from having been fully used.