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US-bound Audi A3 Sedan spied testing

As the Audi A3 sedan gets closer to its debut, Audi has camouflaged prototypes to take it on the streets for final testing. Last time we saw the A3, it was testing almost in the buff, but it was on a closed track so our spy shooters were kept at quite a distance.
Now that the newest Audi sedan is testing on public roads, our latest batch of spy shots gives us a more detailed look at the entry-level luxury player despite the swirly camo. Except for the oversized wheels and the fancy exhaust outlets and door mirrors, the production version of the car should look almost identical to the A3 sedan concept we saw in Geneva a couple years ago. Some of the details we can see include a good-sized panoramic roof that stretches almost halfway into the rear passenger space and signature Audi LED-accented headlights and taillights.

Audi boosts A3 Sportback e-tron plug-in hybrid production to 50 a day

Should we try to translate "Damn the torpedoes, full speed ahead" into German? Audi might force us to do that. That's because the German automaker has stepped up production of its new plug-in vehicle – the A3 Sportback e-tron plug-in hybrid – which is never a bad thing. Audi was circulating prototypes of the PHEV as early as 2012 and launched production this summer at a clip of 30 vehicles a day. Now, the company is saying that it's upped that daily production rate to 50. That's not exactly Ford F-150 manufacturing territory, but it's a pretty good sign that more Europeans are clamoring for the plug-in than Audi expected. The A3 E-Tron is priced at about $51,000 in Germany and pairs a 1.4-liter gas-powered engine with an electric motor to produce 204 horsepower and get the car from 0 to 60 miles per hour in less than seven and a half seconds. More impressively, the A3 Sportback e-tron plug-in hybrid can go 30 miles on electricity alone plus another 550 miles on gas power, and gets a Euro-based fuel-economy rating of a monstrous 156 miles per gallon. Check out Audi's press release below and take a look at our drive impressions here. On the line and on time: Production of the Audi A3 Sportback e-tron • First plug-in hybrid model drives off the assembly line in Ingolstadt • Assembly processes integrated into the A3 line • Maximum safety for employees, top quality for customers Production of the Audi A3 Sportback e-tron: Assembly – On the engine and component assembly line, the electric motor and transmission are fitted to the engine. Approximately 50 cars every day, with the same timing and on the same assembly line as the other models: Audi is now ramping up production of the Audi A3 Sportback e-tron*. The premium manufacturer is producing its first plug-in hybrid model at the brand's main plant in Ingolstadt. "We started series production of the Audi A3 Sportback e-tron in the summer," said Dr. Hubert Waltl, Board of Management Member for Production at AUDI AG. "Most of the assembly work is integrated into the A3 line; no separate manufacturing is necessary. That demonstrates the flexibility and efficiency of our production planners and employees." With the Audi A3 Sportback e-tron, Audi is launching the mobility of the future. The compact five-door combines a 1.4 TFSI combustion engine with a 75 kW electric motor, resulting in a total system output of 150 kW (204 horsepower).

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.