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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.

Behind the scenes of BMW's 'Driftmob' [w/videos]

All this, for one minute and 47 seconds of action-packed footage with no official plot.
We arrive in Cape Town, South Africa, on the third and final practice day for the drivers of a BMWStories internet video called The Epic Driftmob feat. BMW M235i. We are immediately whisked to a large, empty parking lot on the outskirts of Cape Town, where tires are squealing and chunks of rubber are flying as five red BMW M235i coupes churn up more smoke than a California wildfire. And the smell - it smells like heated metal, the kind of thing rev limiters are made for. Times five.

Plug In 2014: BMW i DC Fast Charger is poised to change the EV game

It looks like it's just a blue box on a pole, but BMW's new i DC Fast Charger represents a much bigger deal than just the lowest-cost SAE Combo Charger on the market. BMW sees it as the key to getting more drivers into electric vehicles. As Robert Healey, the EV infrastructure manager for BMW of North America told us, "For [BMW], the future is clear. DC charging really is the future." "DC charging really is the future." – Robert Healey, BMW We spoke with Healey at the Plug-In 2014 conference in San Jose, CA last week about the promise of the new $6,548 DC fast charger. "The strategy is pretty simple," he said. "BMW wants to get as many DC Fast Chargers out there as possible. We're not in the charging business, we're in the EV business and to support the sales of our cars, we have identified some key areas: home charging, public charging and assistant services for EV drivers." That's why the first of the new blue boxes will be installed at the 285 i dealers in the US, many of whom already installed the cables needed for fast charging when they put in the Level 2 chargers, said BMW's Cliff Fietzek, manager of connected eMobility. Even if you haven't gotten a site ready for a DC fast charger, the installation costs for BMW's unit are lower because you don't need to pour concrete (for the wall unit) and the SAE Combo connector plug costs "significantly" less than the competing CHAdeMO plug, Fietzek said. One minor drawback to the BMW DC fast charger compared to the more expensive traditional, full-size DC fast chargers is that the 24kW BMW fast charger allows you to charge to 80 percent full in 30 minutes, while the bigger units can do the job in 20. The good news for EV drivers with SAE Combo cars (which, in the US, means the Chevy Spark EV and the VW e-Golf) is that any driver with a Combo plug car and a ChargePoint card will be able to use the BMW stations. In fact, BMW is talking with both GM and VW on where to install SAE Combo stations in the US so that there is minimal duplication of effort. In other places, BMW is working with other automakers, including Nissan, which uses a competing fast charging standard. "In Great Britain, we are installing triple chargers, the CHAdeMO, SAE Combo and the high-power, three-phase AC that can go up to 43 kW to support the Renault [EVs] and others," Fietzek said.