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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.

Driving the Honda Ridgeline and marveling at Tesla | Autoblog Podcast #638

In this week's Autoblog Podcast, Editor-in-Chief Greg Migliore is joined by Consumer Editor Jeremy Korzeniewski and Associate Editor Byron Hurd. They start off talking about why more people should buy the Honda Ridgeline, because it's a pretty darned good truck. Next, Byron talks about some Hyundais. He shares his experiences with the 2020 Sonata Hybrid and talks briefly about the prototype 2021 Elantra currently occupying his driveway. Up next, Jeremy shares his feelings about the BMW X1 crossover he spent some time with, prompting the gang to mull over the notion of BMW's modern interpretation of "Ultimate Driving Machine." After that, Byron talks about towing his 1990 Mazda Miata with the 2020 Infiniti QX80, and then they wrap up with some discussion of the mystery surrounding the Ford Maverick and some comments on the current state of Tesla. Autoblog Podcast #638 Get The Podcast iTunes – Subscribe to the Autoblog Podcast in iTunes RSS – Add the Autoblog Podcast feed to your RSS aggregator MP3 – Download the MP3 directly Rundown Hauling dirt with the 2020 Honda Ridgeline Driving the 2020 Hyundai Sonata Hybrid Discussing the 2021 Hyundai Elantra Driving the 2020 BMW X1 Towing a 1990 Mazda Miata with a 2020 Infiniti QX80 News Ford Maverick tailgate stamping leaks; we may see the whole thing in 2021 Tesla reports profit for fourth straight quarter, setting it up to join S&P 500 Feedback Email – Podcast@Autoblog.com Review the show on iTunes Related Video:

BMW i3 gets official worldwide

Even though we recently drove a near-production version of the BMW i3, the car still wore light exterior and interior camouflage. Today, BMW took off that little bit of camo and made a big announcement: The i3 will go on sale in the US for $41,350 in the second quarter of 2014. That does not include any state or federal incentives that could lower the price or the $925 destination fee. The i3 will debut with three trim levels, which BMW is referring to as Worlds: Mega (standard in the US), Giga and Tera.
The BMW i3 is chock-full of new technology afforded by its design as an EV from the start of development, which has resulted in a vehicle layout unique to the i3. BMW has named it LifeDrive architecture, and it features the Life Module and the Drive Module. The Life Module is the i3's pillar-less passenger cell, which is the first mass-produced monocoque made of carbon fiber reinforced plastic (CFRP). The tougher-than-steel material is also 30-percent lighter than aluminum, which contributes to the i3's relatively light weight of 2,700 pounds (preliminary US figure) and, in turn, increases its energy efficiency. Expect more of this technology to find its way into future BMWs.
The Drive Module, a 100-percent aluminum chassis mounted under the Life Module, houses everything that makes the i3 go. It includes the 22-kilowatt, 450-pound lithium ion battery mounted as centrally as possible, and provides power to a rear-mounted electric motor that turns the rear wheels. With 170 horsepower and 184 pound-feet of torque from zero rpm, the single-gear i3 can accelerate from 0-30 miles per hour in 3.5 seconds and 0-60 mph in about 7.0 seconds, but it has a top speed of only 93 mph. BMW says the i3 has a real-world EV range of 80-100 miles, and the standard charger can fill the battery in three hours. Opt for the SAE DC Combo Fast Charger and 30 minutes is all it takes for a full charge; 20 minutes will bump the battery to 80 percent. For customers who have range anxiety, BMW gives them the option to install a 34-hp, 650cc two-cylinder generator as a range extender for the electric drive system.