New BMW Electric Car Features Carbon Composites

BMW says it will cut more than 600 lb from the weight of itsfirst electric vehicle through extensive use of carbon-fiber-reinforcedplastics (CFRP).

Engineers at BMW Group aredeveloping the Megacity architecture from scratch and will use CFRP for bodypanels and some interior parts. It represents the most extensive use ever ofcarbon composites in cars. The new electric vehicle is due in 2013.

A key factor is a back-integrated approach to producingcarbon composites that will improve their cost structure by a factor of morethan 50 percent.

SGL Automotive Carbon Fibers, a joint venture of the BMWGroup and SGL Group, is building a plant in Moses Lake, WA, to produce carbonfiber. The plant will operate two lines, each with annual capacity of 1,500metric tons. The first line is expected to be commissioned late next year.

"The decision to build the carbon fiber plant in Moses Lakewas based primarily on the availability of renewable clean hydropower andcompetitive energy costs in the state of Washington," says Joerg Pohlman,managing director, SGL Automotive Carbon Fibers. "Favorable infrastructureconditions, existing utilities, a skilled labor force and fast permittingprocesses were also important contributing decision factors."

The plant will produce industrial-grade carbon fiber, whichcosts less than half ($10 versus $25 per pound) the grade used in high-end racecars. SGL will also make use of industrial scrap, a concept under closeanalysis at nearby Boeing, which uses CFRP in the Dreamliner787.

The plant's output initially will go to the Megacity, whichwill be assembled in Leipzig, Germany. The four-seat hatchback will use aluminumfor chassis components. A lithium-ion battery with about 35 kWh of capacity willbe located below the vehicle's floor and is expected to offer about 100 milesof range.

BMW is not a stranger to CFRP. It molds its own roofs withthe material for the M3, a racing car that recently competed in the Petit LeMans.

New BMW Electric Car Features Carbon Composites_B