BMW i3 in detail – the world’s first mass-produced car to be made primarily of carbon-fibre

BMW_i3_carbonfibre_production_05

The revolutionary BMW i3 premium all-electric vehicle made its global debut just a few days ago, representing a new form of sustainable mobility. There’s a lot to get excited about here. BMW claims that this is the future, now.

A crucial aspect of the BMW i3 is its groundbreaking LifeDrive architecture. The all-carbon-fibre platform is so lightweight, giving this electric car enough pep to put it in the same performance ballpark as today’s sub-200 hp hot-hatches such as the Peugeot 208 GTi and Volkswagen Polo GTI.

Consistent lightweight construction is especially important for electrically-powered vehicles, as, alongside battery capacity, the vehicle weight is the limiting factor for the range. The lighter the vehicle, the greater the range, because the electric motor has less mass to move when accelerating.

This concept calls for the use of modern lightweight construction materials. BMW’s answer? Carbon-fibre, which until now is used exclusively in top-tier vehicles where production cost is not a limiting factor. It obviously is for a mass-produced car like the BMW i3, though.

Previously, large-scale use of carbon-fibre was deemed too expensive by others. Through innovative production processes, BMW Group is now the only automobile manufacturer to possess the necessary expertise for industrialised mass production of carbon-fibre.

The entire carbon-fibre manufacturing process, which starts in Moses Lake in the US, then passed to Germany in Wackersdorf and Landshut and on to final construction in Leipzig, has been carefully controlled by BMW to conserve the environment and resources involved.

BMW_i3_carbonfibre_production_02

It’s a long and carefully thought-out process. The i3’s basic bodyshell is made up of around 150 parts, one-third fewer than in a conventional sheet steel body. In construction and assembly, there’s no noise pollution from screwing or riveting, no sparks flying during welding, as only adhesive technology is used.

The long curing time dictated by traditional carbon-fibre production has been accelerated for the i3. What would take days for small batch productions is now completed within minutes through use of newly-developed adhesive, thermal and bonding processes.

Every little detail and new innovations add up to make the use of carbon-fibre financially and physically viable for a large-scale, mass-produced project – something that is unheard of before. The revolutionary production concept of the BMW i3 sets new standards in the use of the exotic material in an everyday car.

Ultimately then, the new BMW i3 is the first mass-produced car to be made primarily of carbon-fibre, but with manageable costs involved. It will still be priced like a BMW, but considerably lower than anything else with a state-of-the-art carbon-fibre construction. Now, this is a cost-cutting process that you won’t look down upon with condescending eyes.

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Hafriz Shah

Preferring to drive cars rather than desks, Hafriz Shah ditched his suit and tie to join the ranks of Malaysia’s motoring hacks. A car’s technical brilliance is completely lost on him, appreciating character-making quirks more. When not writing this ego trip of a bio, he’s usually off driving about aimlessly, preferably in a car with the right combination of three foot pedals and six gears.

 

Comments

  • pooyu on Aug 02, 2013 at 6:21 pm

    price it below 100k then can call it future..

    Like or Dislike: Thumb up 4 Thumb down 0
    • Heute unten €100k, mogen unten RM100k
      It’s only a matter if time, a long time, this is only the first step.

      Like or Dislike: Thumb up 1 Thumb down 0
  • Of all the technological innovation of the I3, nothing contributes better for the advancement of automobile world more than able to make CFRP available to the joe public. It’s important to note that structural integrity is one of the key features in automobile safety(something less talk in PR), as an added benefit it also contributes for a better performance. What we have here is a benchmark, I hope in 30 yrs time at least 50% of new cars will be made out of Carbon Fiber. Thank you BMW, Dank für Ihre Beitrag

    Like or Dislike: Thumb up 5 Thumb down 2
    • frenzyaustin on Aug 02, 2013 at 9:26 pm

      Nissan Leaf can achieve near same mileage with a heavier and bigger body but much less price. But the most advance EV is Tesla, that just god damn, real innovator of EV!
      But BMW is really pushing the boundary of using CFRP, the cheapest CFRD vehicle you can get in the market, and it will change the future of automobile.

      Like or Dislike: Thumb up 4 Thumb down 0
  • once accident can consider junk already??

    can carbon-fibre be fixed? any normal workshop can fix it or must send to BMW?

    just curious..

    Like or Dislike: Thumb up 11 Thumb down 0
  • Carbon fibre…. if ding a corner, may need to change whole panel?

    Like or Dislike: Thumb up 5 Thumb down 0
    • Body panels are all plastic and designed to be very easy to replace. It is designed to be a city car, after all. Carbon fibre is used for the body structure. Panels go on top of it.

      Like or Dislike: Thumb up 0 Thumb down 0
  • mamamia on Aug 03, 2013 at 1:53 pm

    using carbon fibre means it expensive…

    Like or Dislike: Thumb up 0 Thumb down 0
  • shawal on Aug 03, 2013 at 11:51 pm

    RWD ….still a BMW
    tho Mitsu I-miev is the pioneer ( to my knowledge at least )

    Like or Dislike: Thumb up 0 Thumb down 0
  • steve on Aug 05, 2013 at 12:26 pm

    Light but not so safe. Just like F1 car when accident it will break into pieces……

    Like or Dislike: Thumb up 0 Thumb down 2
 

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