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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.

Submit your questions for Autoblog Podcast #334 LIVE!

We're set to record Autoblog Podcast #334 tonight, and you can drop us your questions and comments via our Q&A module below. Subscribe to the Autoblog Podcast in iTunes if you haven't already done so, and if you want to take it all in live, tune in to our UStream (audio only) channel at 10:00 PM Eastern tonight.
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BMW i3 starts near $35,000; NA first deliveries January 2014

While in Germany at the first early pre-production drives of the hotly anticipated BMW i3, BMW people finally hinted at a price ballpark. Numbers being tossed around by pundits have actually been pretty close to what BMW is discussing internally - between $35,000 and just over $40,000. We have been assured now that the base price, should one choose to buy and not lease in the Euro zone, is just over 35,000 euro, with some big taxes included in that price. In the US, the starting price for the fully EV plug-in version should be $34,500 or right thereabouts. In addition to new pricing, we've also gotten our best-yet look at the i3, with the freshly uncovered spy shots you see here.
European deliveries begin in November of this year for the fully electric version of the rear-wheel-drive i3 with 168-horsepower and 184 pound-feet of torque. The e-motor mounted over the rear axle is supplied with energy by the 22-kWh lithium-ion battery pallet under the passenger compartment. Recharging happens in any of three ways: public or personal garage plug-in charge station (garage version not included in the price), the onboard system's Pro Eco mode that adds resistance to the drivetrain in a type of rolling brake energy recuperation, or through the normal brake energy and off-throttle coasting regeneration more common to EVs. Range on a full charge of this drivetrain is said to be upwards of 100 miles under hyper-miling conditions.
Perhaps the best bit of news is that the alternative, range-extending, two-cylinder 600cc engine supplied by BMW Motorrad for the hybrid version of the i3 - mounted in the rear together with the e-motor - will add only 2,000 euros in Europe and about $2,000 in the US. This is a range-doubling solution that could have brought a much higher price gouge, so thank you, BMW. The hybrid e-drive i3 version arrives a couple months after the full-EV launch version. Remember that, unlike the very similar system for the Chevrolet Volt, the system in the i3 supplies no mechanical torque to the driven axle and is only used as a generator (a system BMW first used last year in the 1 Series-based Active ). The US is seen as the clear number one market for the i3.