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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 tops Consumer Reports' brand rankings while Tesla leads domestics at eighth

Tesla supplanted General Motors' Buick division as the top-ranked US automaker in Consumer Reports annual brand rankings, though the electric-vehicle maker finished eighth among global automakers. Buick had finished atop CR's domestic car-brand list for three years before Tesla leapfrogged it. Scores were calculated from a combination of performance, owner satisfaction, and reliability. CR noted that Buick scored big on reliability but not so high on performance, while Tesla appeared to present the opposite case. Volkswagen's Audi division repeated as the best overall brand for the second straight year, beating out VW's Porsche unit, BMW, Toyota's Lexus division, and Subaru. Kia and Mazda followed those brands, while Honda finished ninth, between Tesla and Buick. Consumer Reports took results from 31 brands. Reliability issues related to the Toyota Tacoma helped drop that Japanese automaker out of the top 10. Take a look at CR's results for its Annual Brand Report Card here. That Tesla, Audi, and Porsche placed so high is topical, given some of the issues plaguing those automakers. Audi, Porsche, and their parent VW have been coping with the effects of the diesel-emissions scandal that broke back in 2015. The scandal has cost Europe's largest automaker billions of dollars, and forced VW to put a stop-sale on diesel-powered cars in the US in late 2015. And while the Tesla Model S improved from the "worse-than-average" label CR gave it in its 2015 Annual Auto Reliability Survey, the problematic falcon-wing doors on the Tesla Model X SUV pulled that model's reliability scores lower last year. Additionally, the Model X's climate-control system and door locks have also caused issues. Toyota and Lexus finished atop CR's reliability rankings last year. Related Video:

Audi Sport Quattro Concept to race into Frankfurt

Audi has pulled the official wraps off its new Sport Quattro Concept, which will be debuted at the 2013 Frankfurt Motor Show. The automaker is understandably keen to draw inspiration from its classic Quattro line of automobiles, specifically the original Ur-Quattro from 1980 and the short-wheelbase Sport Quattro that took part in rally racing and set a record at the Pikes Peak Hill Climb in 1987. A massive dose of modernity comes courtesy of its 700-horsepower plug-in hybrid powertrain.
There is a clear link in the styling of the Sport Quattro Concept to Quattro coupes of the past, from the large flat surfaces that make up its C pillars to the blisters over the fenders and the basic headlamp shape (equipped as they are with Audi's Matrix LED technology). Pay special attention to the car's grille, which introduces a slightly new design language that is expected to be seen in the next generation of Audi's mainstream production models.
The interior of the Sport Quattro Concept is a refreshing departure from Audi's admittedly attractive and useable design, with sharp lines and lots of visible carbon fiber. There are seats for four occupants inside, along with a comparatively generous cargo area measuring 10.59 cubic feet.