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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.

Watch Audi R8 give Birth to RS3

In the cold light of reality, it's a fairly dubious proposition to suggest that the Audi RS3 Sportback shares much of a mechanical relationship with an R8. One of them is supercar with a snorting V10 and lithe body, while the other is a still-capable hot hatch with roots lower in the brand's range. However, marketing doesn't necessarily have to sell real life, and Audi's advertisers are nailing the emotional pull of these two models in a spot called Birth. With dramatic music and a sci-fi aesthetic, the R8's V10 roars as the supercar stretches and deforms, and eventually the hot hatch gets plucked from its metallic loins. Regardless of how closely these two models are related, this commercial looks and sounds fantastic. With the US rumored to get the RS3 in sedan form at some point, hopefully we get a tweaked version of this ad.

Audi A3 E-Tron could launch in October in US

When we test drove the Audi A3 E-Tron plug-in hybrid in Europe last summer, Audi was talking about the vehicle's introduction in the US, but left the exact date up in the air. Summer or Fall 2015 was as specific as anyone was willing to get. Now it looks like the plug-in will arrive in October. One of the rumors we heard over the last few months was that the A3 E-Tron was not ready for the US because of poor cold-weather performance. From what we've heard, under a certain temperature limit, the engine needs to kick in at all times, no matter what the battery state of charge is, and some European A3 E-Tron owners are disappointed that their EV sometimes isn't all that electric. Audi's solution needs to take into consideration how to balance utilization of battery power in less-than-optimal temperature ranges with passenger comfort and how any excess battery use impacts longevity. Audi's "fairly conservative" position will "ensure the long-term credibility of the E-Tron platform and plug-in technology." - Brad Stertz Brad Stertz, the corporate communications manager for Audi of America, told AutoblogGreen that, "Audi is taking a fairly conservative position to ensure the long-term credibility of the E-Tron platform and plug-in technology, while still creating the best experience for our drivers in each region. Overall, I think it is safe to say low temps affect performance in all vehicles to some degree, but that plug-ins face unique challenges that we will continue to work through with the A3 e-tron and other plug-in models to follow." Stertz also said in April that the US configuration for the A3 E-Tron was still being fine-tuned. For example, there were some software differences under consideration to meet US driving preferences. Looks like we only have four more months to wait and see. Related Video: