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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 celebrates 30 years of M5 with 600-hp super sedan

It's been 30 years since BMW rolled out the first M5, and while displacement and cylinder count may have fluctuated over those past three decades, output has only increased. The first-generation E28 M5 packed a 3.5-liter inline-six with 252 horsepower and 243 lb-ft of torque. The second-gen E34 model that followed added an extra 100 cc (and later 200 more) to produce 310 hp and 266 lb-ft. The E39 followed with a 4.9-liter V8 churning out 394 hp and 369 lb-ft, replaced by the award-winning 5.0-liter V10 in the E60 with its 500 hp and 380 lb-ft before BMW rolled out the latest model with a 4.4-liter V8, its twin turbos making up for the two dropped cylinders and 600 cc of displacement to produce 560 hp and 502 lb-ft of torque. But even that's being left in the dust by the new special edition you see here.
The 30th Anniversary Edition BMW M5 packs that same 4.4-liter twin-turbo V8, but cranks the output up to a nice, round 600 horsepower and a solid 516 lb-ft of torque to go with it. That makes it more powerful, not only than any M5 that's come before it, but also any of its rivals. The Jaguar XFR-S and Audi RS6 Avant (the latter only available as a wagon and not in North America) both lag behind this ultimate of Ultimate Driving Machines; only the Mercedes-Benz E63 AMG trumps it on torque (but not on power), with 531 lb-ft in stock form and 590 in the S-Model.
As a result, the 0-60 time drops from a quoted 4.2 seconds in the stock M5 to a scant 3.7 in the 30th Anniversary edition (just one tick behind that twistier E63 S). The special M5 also comes with the Competition Package as standard, as well as a dedicated control module for the Active M Differential, a special Frozen Dark Silver matte finish, 20-inch alloys and black chrome badges. Special badges abound inside as well, where you'll also find black leather and Alcantara upholstery and aluminum trim. There'll even be a dedicated one-day course offered to owners at The Thermal Club in Palm Springs, CA, to further sweeten the deal.

BMW recalling nearly 570,000 1 Series, 3 Series and Z4 models over electrical issue

BMW is recalling roughly 570,000 vehicles in the United States and Canada due to faulty battery cable connectors that can fail, causing the engines in these cars to stall. Of the nearly 570,000 affected vehicles, just over 504,000 are here in the US.
The affected vehicles include 1 Series coupes and convertibles (both 128i and 135i) from the 2008 to 2011 model years; 3 Series sedans, coupes, convertibles and sport wagons (both 328i and 335i) from the 2007 to 2011 model years; and Z4 roadsters from the 2009 to 2011 model years.
According to the National Highway Traffic Safety Administration, "the connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time," which can eventually lead to a break in the electrical connection and a loss of power in the vehicle. If the car loses power, the engine can stall, which could possibly lead to a crash. The Detroit News reports that BMW knows of one minor collision in Canada as a result of this problem, but no injuries.