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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.

New BMW i3-like Visio.M EV concept uses lightweight resin

It's not a new version of the BMW i3, but an updated version of a lightweight concept car from SABIC, BMW, the Technical University of Munich, Daimler and others does bear a certain resemblance to the well-designed plug-in city car. From the black "glass" in the hatch to the angled line tail lights to the up-and-down window line, you can see a sort of family resemblance (see an i3 comparison photo here). And, of course, they both have an electric powertrain. But the changes made to the new lightweight urban electric concept vehicle is more of an exercise in what's possible rather than a way to evolve the i3 and i8 into a broader i family of vehicles. Even so, what we see here is interesting, since SABIC found all sorts of new ways to take weight out of the car as part of the Visio.M (Visionary Mobility) project, which was first announced in 2012. Let's start with the window material, which as you might guess from the quotation marks above, is not made of glass but is instead SABIC's Lexan polycarbonate (PC) resin plastic. The lower weight (the PC helps shed about 29 pounds) adds two miles of range while the PC resin has better thermal conductivity compared to glass and so does even more because the HVAC system can be more efficient. According to SABIC's computational fluid dynamics analysis, an extra 9-10 miles of range, in fact. Without the battery, this concept weighs just 992 pounds. Remember, BMW already made a lot of weight-reduction measures in the i3 thanks to carbon fiber reinforced plastic, so to make the "glass" lighter would only help boost efficiencies on a production vehicle that uses a resin like this. Read more below. SABIC's LEXAN™ resin delivers weight savings and thermal efficiency for new ultra-lightweight electric car concept developed by BMW-led Visio.M Consortium Munich, October 20, 2014 Today, at the Technical University of Munich (TUM), BMW, Daimler, TUM scientists and a consortium of industry participants showcased a lightweight urban electric concept vehicle with various advances, including an all-plastic design of the car's windows. The windows are made of LEXAN resin, a polycarbonate (PC) material, and coating technologies from SABIC, a leading developer of PC glazing for automotive windows and many other thermoplastic solutions for the automotive industry.

BMW 2 Series Active Tourer is the world's first front-drive Bimmer [w/videos]

While BMW has been showing concepts for its Active Tourer for over a year, they never seemed entirely real. Why would BMW, a company that has built its image on sporty, rear-wheel drive sedans, move into the five-door, front-wheel-drive market? The answer is still not entirely clear, but the new BMW 2 Series Active Tourer is very real. It launches in Europe later this year and is rumored to come to the US in 2015.
To brand purists, a front-wheel drive BMW may seem anathema to everything the company has built, and the production Active Tourer has clearly been built to provide drivers with a luxurious but utilitarian package first and foremost. It is 170.9 inches long and rides on a 105.1-inch wheelbase, but despite its compact dimensions, its high roof allows for 16.53-cubic-feet of cargo space with the rear seats up or 53.33 cubic feet with them folded flat. Its general appearance is nearly identical to the previous concepts, except with a blunter nose and cleaner lines. The front end wears BMW's traditional dual circular headlights and naturally, while the profile incorporates the company's traditional Hofmeister kink into the greenhouse's rear pillar. The interior has been designed to be especially useful with a sliding rear seat, adjustable rear backrests, fold-flat backrests and optional features like an automatic tailgate and panoramic sunroof.
Unlike both previous concepts, none of the Active Tourer models at launch use hybrid power. For Europe, the hatchback is going on sale with three engine options. The basic version is the 218i Active Tourer with a 1.5-liter, turbocharged three-cylinder with 134 horsepower that we just previewed in the 2014 Mini Cooper - good enough for average fuel economy of 48 miles per gallon in the EU cycle when equipped with a six-speed manual. The next step up is the 225i Active Tourer with a 2.0-liter turbocharged four-cylinder that makes 228 hp and offers 39-mpg average fuel economy. Finally, there is the there is the 218d Active Tourer with its 148-hp, 2.0-liter turbodiesel and 57 mpg average fuel economy on the EU cycle. A six-speed manual is standard on all of them, but there is a six-speed automatic option for the 218i and eight-speed automatics available for the 225i and 218d. All-wheel drive will be available on future models.