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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.

BMW recalls 6,073 units of i3 and Minis to replace airbag

BMW is replacing the passenger's side front airbag module on 6,073 vehicles in the US because of a supplier's manufacturing issue with the part. The affected models include the: 2014-2015 i3; 2014-2016 Mini Hardtop 2 Door Cooper and Cooper S; 2015-2016 Hardtop 2 Door John Cooper Works; and 2015-2016 Hardtop 4 Door Cooper and Cooper S. Because the airbag components aren't made correctly, they might not deploy with enough restraint in a low-speed collision. BMW isn't aware of any accidents or injuries from the problem, but this is still obviously a safety concern. According to company spokesperson David Buchko to Autoblog, customers will be notified about the issue by mail in November. As always, dealers will perform the replacements at no cost to owners. Related Video: RECALL Subject : Passenger Frontal Air Bag May not Deploy Properly Report Receipt Date: OCT 07, 2015 NHTSA Campaign Number: 15V628000 Component(s): AIR BAGS Potential Number of Units Affected: 6,073 All Products Associated with this Recall Vehicle Make Model Model Year(s) BMW I3 2014-2015 MINI COOPER 2014-2016 MINI COOPER S 2014-2016 MINI JOHN COOPER WORKS 2015-2016 Details Manufacturer: BMW of North America, LLC SUMMARY: BMW of North America, LLC (BMW) is recalling certain model year 2014-2016 MINI Cooper S and MINI Cooper two-door vehicles, 2015-2016 MINI John Cooper Works and MINI Cooper S and MINI Cooper four-door vehicles and 2014-2015 BMW i3 vehicles. Due to a manufacturing error, the passenger frontal air bag may not deploy properly in a low speed crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 208, "Occupant Crash Protection." CONSEQUENCE: In the event of a vehicle crash, an air bag that does not deploy properly increases the risk of injury to the front seat passenger. REMEDY: MINI and BMW will notify owners, and dealers will replace the passenger frontal air bag module, free of charge. The recall is expected to begin on November 20, 2015. Owners may contact MINI customer service at 1-866-825-1525 and BMW customer service at 1-800-525-7417. NOTES: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov. BMW Statement: BMW has informed NHTSA of its intention to voluntarily recall approximately 923 BMW i3 vehicles to replace the passenger-side front airbag module.

BMW M4 sheds some camouflage for latest test run

Last time we saw the upcoming BMW M4 out testing, it was heavily clad with camouflage and decidedly homely looking (as most early development mules are). But in this latest set of photos, the M3 coupe successor has started to come into its own skin, and we're seeing a shape more closely akin to that of a rendering we brought you a few months back.
Unsurprisingly, the M4 coupe looks very similar to the 4 Series Concept that BMW debuted at the Detroit Auto Show earlier this year. And while non-M version of the 4er will likely look a bit more sedate, these spy shots clearly show an aggressive front fascia, large wheels and the usual quad-exhaust rounding out the rear end.
Naturally, the M3 sedan will launch before this M4 coupe (and convertible), and powertrain details are still unclear as of this writing. We understand that the current M3's naturally aspirated V8 will be axed in favor of some sort of turbocharged six-cylinder engine, and we've heard plenty of rumors as to what, exactly, it might be, but we have yet to hear any official confirmation.