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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.

Why are all US-bound BMW i3 EVs with range extenders stuck at port?

The first BMW i3 EVs have been delivered in the US, but in a quirk of the rules, none of them have been the range-extended versions. Long-time BMW electric vehicle driver Tom Moloughney discovered this fact the hard way. His i3 REx has been sitting at a New Jersey port for over a week and he's getting impatient. The problem is something Moloughney calls a "Monroney Hold." So, instead of sitting there fuming, Moloughney did a bit of research and discovered that the problem is something he calls a "Monroney Hold." He says that "the EPA certification has not been completed so BMW doesn't have a Monroney label (window sticker) to post in the window before the car leaves the port, which is required by law. The range extender option changes (shortens) the car's electric range, and also requires an official MPG rating so BMW couldn't use the same Monroney label as they did for the all electric i3." You can read more on his website, but it turns out that the story isn't so simple. For one thing, the EPA testing has been finished. Washington State representative Chad Magendaz told Moloughney that he asked the EPA for an official statement and got the following from Linc Wehrly, Director of the Light-Duty Vehicle Center Compliance Division: "EPA tested the i3 REx and provided the results of that testing to BMW on May 13th. EPA is not aware of anything that would prevent BMW from importing the vehicles since May 13th." Then there's the official word from BMW. Spokesman Dave Buchko told AutoblogGreen that: We are moving as quickly as possible to release the first BMW i3 Range-Extender models to BMW i Centers. Receipt of test data from the EPA is one step, but not the final step, in the process of receiving certification from the EPA. Rules do not permit the release of vehicles for sale until EPA labels are finalized, produced and affixed to any vehicle. Barring any unforeseen delays, we expect that to happen by the end of this week. We have never certified a vehicle like this before. We are taking every precaution to make sure that everything is done in a timely, but more importantly correct manner. In that Monroney labels cannot be produced until the EPA certification process is complete, the characterization [of a "Monroney Hold"] is not technically incorrect, but there is more to it than that, as is often true in life. On a lighter note, BMW donated a loaded i3 to Brad Pitt's Make It Right charity foundation as a fundraiser. Read about that below.

Car cocktails and Risky Business Porsches with Brett Berk | Autoblog Podcast #502

On this week's podcast, Mike Austin and David Gluckman are joined by a special guest, Autoblog contributor Brett Berk. The three discuss cars in film and TV as well as Brett's series on car-themed cocktails. There is of course a recap of what they've all been driving lately, and the episode wraps up with Spend My Money buying advice to help you, our dear listeners. The rundown is below. Remember, if you have a car-related question you'd like us to answer or you want buying advice of your very own, send a message or a voice memo to podcast at autoblog dot com. (If you record audio of a question with your phone and get it to us, you could hear your very own voice on the podcast. Neat, right?) And if you have other questions or comments, please send those too. Autoblog Podcast #502 The video meant to be presented here is no longer available. Sorry for the inconvenience. Topics and stories we mention 2017 Chevrolet Bolt EV - Autoblog's 2017 Technology of the Year Car award winner 2017 Ford Shelby Mustang GT350R 2016 Kia Soul EV 2017 Audi A4 sedan The story of the Risky Business Porsche 928 The Taxi Cocktail took us for a ride The myth and mystery of The Bentley Cocktail Used cars! Rundown Intro - 00:00 What we're driving - 01:50 Brett Berk interview - 21:12 Spend My Money - 39:44 Total Duration: 54:02 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 Feedback Email – Podcast at Autoblog dot com Review the show on iTunes Podcasts Audi Bentley BMW Chevrolet Maserati Mercedes-Benz Porsche kia soul ev Chevrolet Bolt porsche 928 ford shelby mustang gt350r cocktails