2004 Audi S4 Quattro, Brembo, Coilovers, Milltek Exhaust, Hre's, 53k Miles on 2040-cars

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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 planning RS Q7 performance crossover

Audi resisted getting into the crossover market altogether until it launched the original Q7 in 2005, and held back from producing a performance crossover until it caved first with the SQ5 and then with the RS Q3, both in 2013. And now that the tide has washed over it, Ingolstadt's next plan, according to Top Gear, is to launch a performance version of the new Q7. Though it remains unclear whether it would carry the S or RS badge, the performance-oriented version of the new Q7 will surely benefit from the hundreds of pounds in excess weight Audi managed to trim off the latest model over the one it replaces. Also unclear is whether said hi-po Q7 would go with a diesel or a gasoline engine. The diesel option would more likely go the S route than the full RS, but wouldn't be likely to make it to the States if it were only offered as a diesel. With the SQ5, it's worth noting, Audi offers a TDI diesel version in Europe and a gasoline TSI in North America, so we wouldn't be surprised to see it take a similar approach with the larger model as well. Whatever it does pack under the hood, though, the SQ7 or RS Q7 would be facing some stiff competition from the likes of the Mercedes GL63 AMG, BMW X5 M and Range Rover Sport SVR – not to mention corporate cousins like the Porsche Cayenne Turbo and upcoming Bentley Bentayga – while giving the Volkswagen group a bigger slice of that exclusive but expanding pie.

Production 4.0: Audi plans for the smart factory

Automotive production is becoming more integrated and at the same time has to be more intelligent and more efficient. Flexible production of customized vehicles is one of the big challenges for the future, especially for a premium carmaker like Audi. How will the "Vorsprung durch Technik" brand meet its aim of offering premium quality with added custom flexibility? The company sees the "smart factory" as the key. Whether it's body-color moldings or light-alloy wheels in a special size, almost every car is ordered with some kind of customization, and the demands are increasing. This requires of course already a lot of flexibility. While the variety of models and quality demands are increasing, automotive manufacturers such as Audi are eager to make production sustainable. In an Audi interview, innovation management members Alois Brandt and Henning Loser talk about "production 4.0" and the upcoming "smart factory." How will Audi manage the production site with its very high standards of quality, efficiency, and environmental acceptability? Will the so-called "smart factory," which should be the intelligent factory of the future, only employ robots? Alois Brandt: "With a deep look into the production, I am convinced that our employees and not machines are the relevant working forces behind the Audi brand. Machines can be bought anywhere." Increasing digitalization is paving the way for the smart factory – the intelligent, digitally connected production facility. New high-tech solutions in manufacturing should further increase the high level of quality, while at the same time the assembly work should be easier and result in better ergonomics. Can you give us a clearer imagination of the "smart factory"? Alois Brandt: "There are a lot of ideas. But the big question at the moment is: Which one is really needed and leads into the right direction?" Can you tell us a little bit more about "production 4.0"? Alois Brandt: "The assembly line as we know it in the present will no longer play the same role. If it makes sense, it will be terminated and replaced by – let's call it – a virtual assembly line. The production will be more modular than before and the car will be directed to a production point – a so-called 'island of competence' – where it is needed." Henning Loser: "If the vehicle is to be assembled to the customer's wishes, it is obvious that efficient programming of robots and coordinating with the human workers is needed.