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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 A3 E-Tron plug-in hybrid set to whiz into Geneva

The Audi A3 E-tron, which we drove in prototype form last year, is headed to the 2013 Geneva Motor Show next month. The plug-in hybrid will feature a total of 204 horsepower and 258 pound-feet of torque from the combination of a turbocharged 1.4-liter engine and a 75-kW electric motor. That motor itself is positioned between the internal combustion engine and the machine's six-speed dual-clutch transmission. The setup is good enough to scoot the A3 E-tron to 62 miles per hour in 7.6 seconds and crank out a top speed of 138 mph. Perhaps more impressively, the hatch can whir its way to 80 mph on all-electric power with an EV range of 31 miles.
Audi claims the A3 E-tron gives the world a "realistic glimpse into the future of mobility," so it's a bit unclear if the model will see production. We're encouraged by the specificity of Audi's press release (which is full of stats) and the fact that they don't label this vehicle a concept. You can check out the full press release below and judge for yourself.

The skinny on Delphi's autonomous road trip across the United States [w/videos]

Rolling out of an S-shaped curve along Interstate 95, just past Philadelphia International Airport, the final obstacle between the autonomous car and its place in history appeared on the horizon. So far, the ordinary-looking SUV had traversed the United States without incident. It had gone through tunnels and under overpasses. It circled roundabouts and stopped for traffic lights. Now, on the last day of a scheduled nine-day journey, it was poised to become the first autonomous car ever to complete a coast-to-coast road trip. First, it needed to contend with the Girard Point Bridge. Riding in a rear seat, "I saw that bridge coming, and I thought, 'Oh my gosh, this is going to be a grab-the-wheel moment," said Kathy Winter, vice president of software at Delphi Automotive. The car, an unassuming Audi SQ5 nicknamed Roadrunner, had been well-tested. Back in January, a few inebriated pedestrians fell flat in front of the car during a demonstration in Las Vegas. It was the quintessential worst-case scenario, and the car admirably hit the brakes. More than drunken louts, bridges present a sophisticated challenge for the six radar sensors that feed data to the car's internal processors. Instead of sensing solid objects, radar sensors can read the alternating bursts of steel beams and empty space as conflicting information. "They're a radar engineer's worst nightmare," said Jeff Owens, Delphi's chief technology officer. Girard Point Bridge, a blue skeleton of girded steel that spans the Schuylkill River, might be a bigger challenge than most. Traveling across the lower level of its double decks, the autonomous car's radar sensors had to discern between two full sets of trusses. Cross the Schuylkill, and Delphi's engineers felt confident they'd reach their destination: the New York Auto Show. For now, the sternest test of the trip lay directly in front of them. A Data-Mining Adventure Until that point, the toughest part of the journey had been finding an open gas station in El Paso, TX. Trust in the technology had already been established. The main reason Delphi set out on the cross-country venture with a team of six certified drivers and two support vehicles was to capture reams of data. What better way to do that than dusting off the classic American road trip and dragging it into the 21st century? They did exactly that, capturing three terabytes worth of data across 3,400 miles and 15 states.