Video: How BMW Carbon Fiber is Born - Manufacturing at SGL and Landshut - BMW 3-Series (E90 E92) Forum

Jason · 08-25-2011, 01:20 AM

BIMMERPOST NEWS

Video: How BMW Carbon Fiber is Born - Manufacturing at SGL and Landshut

23
COMMENTS

Below is a video look into BMW's carbon fiber reinforced plastic manufacturing process at the SGL Automotive Carbon Fibers plants, with which BMW has a joint venture, and at BMW's Landshut plant.

BMW has ambitions (see our recent discussions) to reduce the weight of its future vehicles by the incorporation of more carbon fiber (CFRP) into its automobile's materials. As one recent article stated - it is out to create a new infrastructure for carbon-fiber auto manufacturing covering everything from the material to the final product, and in the process open the door for wider use of the material. The company's goal is to bring down the cost of carbon fiber to be competitive with aluminum, making it a viable and common material for widespread use in its cars.

The first big showcase model for this will be the BMW i3 electric vehicle and i8 hybrid electric sports car, which will both utilize plenty of carbon fiber.

BMW's current carbon fiber production chain starts off with sourcing raw material in Otake, Japan, to carbon fiber manufacturing in Moses Lake, Washington, to final material preparation at SGL.

The following videos features the CFRP process at SGL and BMW's Landshut plant in Germany. Listen for the narrations at particular parts in the videos.

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E90Fleet · 08-25-2011, 10:47 AM

Japan-USA-Germany Plant 1-Germany Plant2

Jesal@IND · 08-25-2011, 10:47 AM

Wow incredible find!

rbrown81 · 08-25-2011, 11:37 AM

Wow.

E90 ME · 08-25-2011, 12:08 PM

Only BMW!

silentassasin · 08-25-2011, 12:22 PM

The Obsession of making the ultimate driving machine

mapezzul · 08-25-2011, 01:15 PM

Quote:

Originally Posted by E90Fleet

Japan-USA-Germany Plant 1-Germany Plant2

Precursor from Japan, made to CF thread at Moses Lakes, then woven at Neckersdorf then molded/formed into parts at Landshut then off to Leipzip for assembly/glueing together.

In the end all that travel still yields less carbon emissions than it all happening in Germany because taking the precursor and creatIng CF requires the most energy and that phase is using zero carbon emissions hydro power. There is more to it but that is te big emissions saver.

-M

Voice of reason · 08-25-2011, 01:27 PM

Challenge to BMW M:

Next M3- As much as possible CFRP parts, not so much of price increase- please!!

UltimateBMW · 08-25-2011, 03:03 PM

Quote:

Originally Posted by Voice of reason

Challenge to BMW M:

Next M3- As much as possible CFRP parts, not so much of price increase- please!!

Pretty sure this is already the plan.

kmarei · 08-25-2011, 03:07 PM

all that work for a $2000 part
impressive

James T. Kirk · 08-25-2011, 04:40 PM

^ I know really. I'll never look at a CF part the same again.

fdriller9 · 08-25-2011, 04:56 PM

omg omg omg omg omg omg omg omg omg omg omg omg omgomg omgomg omg

IancoleTX · 08-25-2011, 05:14 PM

That is really damned cool. I would love to work for BMW

xerox445 · 08-25-2011, 05:45 PM

icarbon plant:

JoeyBananaz18 · 08-25-2011, 07:04 PM

Quote:

Originally Posted by Voice of reason

Challenge to BMW M:

Next M3- As much as possible CFRP parts, not so much of price increase- please!!

yea thats basically the point. i dont think it will stop at the M and i line-up. I see extensive use of CF across the board.

SilverII · 08-25-2011, 07:55 PM

nice

kmarei · 08-25-2011, 10:36 PM

Quote:

Originally Posted by James T. Kirk

^ I know really. I'll never look at a CF part the same again.

I always liked CF till I saw all the fake CF parts for the E90/92
Grills, wrapped interior trim, diffusers, splitters, iPhone covers etc
You know the really shinny plasticy looking stuff
turned me off of it
But still getting my next m3 with the CF roof

DriveHard · 08-26-2011, 11:35 AM

Its amazing how clean quiet organized all those factories are...

sad thing if you noticed....... not too many people working around all that machinery.

anerbe · 08-27-2011, 04:24 AM

^ yeah, it is sad, but the best quality control is to avoid manual labor as much as possible.

I've worked with many plants for two different German companies in the US. The production process for serial production is often robust. Often times its the manual labor process that causes the variation in production or improper handling of suspect material.
The only reason more manuacturing is not incorporating such automated processes is due to the high initial capital investments.

CJ421 · 08-27-2011, 08:29 AM

Incredible work. I ordered a BMW CF Performance Front Spoiler (goes under the bumper, very subtle) a few weeks ago, it was expensive and I can see why.

Eeighty8 · 08-27-2011, 02:22 PM

Few interesting points come to mind after watching that.

1. Quality. By moving all the carbon production in-house, they are controlling the quality. They obviously learned from Boeing's mistake of farming out carbon production all over the world for the 787 components.

2. Scale. They are fully committed to moving to composites for their city vehicles and ditching steel eventually. Composites have equal strength as steel, half the weight, and better energy absorption in a crash. I'm sure this is not an overnight process, but it looks like a substantial investment already.

3. Future vehicles. This much effort is not for making little spoilers and trim. All the rumors of the 3 and 4 cylinder motors - guess what cars they are going into? When your car now weighs 30-50% less, it will require a smaller engine. Smaller engine = less production costs. All that and better fuel economy with equal or similar performance. First the i3, etc., then next the MINI's I'm willing to bet.

They are taking a big gamble and technological step forward. It will be interesting to see if/when it pays off.

the infamous... · 08-28-2011, 02:07 PM

08-25-2011, 01:20 AM	#1
Jason Administrator Drives: E90 M3 Join Date: Mar 2005 Location: IoT Posts: 13,978 iTrader: (0)	Video: How BMW Carbon Fiber is Born - Manufacturing at SGL and Landshut BIMMERPOST NEWS Video: How BMW Carbon Fiber is Born - Manufacturing at SGL and Landshut 23 COMMENTS Tweet Below is a video look into BMW's carbon fiber reinforced plastic manufacturing process at the SGL Automotive Carbon Fibers plants, with which BMW has a joint venture, and at BMW's Landshut plant. BMW has ambitions (see our recent discussions) to reduce the weight of its future vehicles by the incorporation of more carbon fiber (CFRP) into its automobile's materials. As one recent article stated - it is out to create a new infrastructure for carbon-fiber auto manufacturing covering everything from the material to the final product, and in the process open the door for wider use of the material. The company's goal is to bring down the cost of carbon fiber to be competitive with aluminum, making it a viable and common material for widespread use in its cars. The first big showcase model for this will be the BMW i3 electric vehicle and i8 hybrid electric sports car, which will both utilize plenty of carbon fiber. BMW's current carbon fiber production chain starts off with sourcing raw material in Otake, Japan, to carbon fiber manufacturing in Moses Lake, Washington, to final material preparation at SGL. The following videos features the CFRP process at SGL and BMW's Landshut plant in Germany. Listen for the narrations at particular parts in the videos. Share this story OTHER STORIES YOU MIGHT LIKE Carbon Fiber BMW Bobsled for USA Bobsled & Skeleton Federation Debuts This Weekend BMW and Boeing to Collaborate on Carbon Fiber Technology Next 7 Series to be First Mainstream BMW Model with Carbon Fiber as a Key Material
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08-25-2011, 10:47 AM	#2
E90Fleet Major General Drives: BMW Join Date: Apr 2005 Location: South Africa Posts: 7,851 iTrader: (0)	Japan-USA-Germany Plant 1-Germany Plant2 __________________ Nominated: Member of the Year, Most Contributing Member BMW if you are reading, I need a job

08-25-2011, 10:47 AM	#3
Jesal@IND Drives: E90 SSII M3 Join Date: Feb 2011 Location: Chicago, IL Posts: 713 iTrader: (1)	Wow incredible find! __________________ IND DISTRIBUTION \| 866.963.4520 \| IND STYLE \| FACEBOOK

08-25-2011, 12:22 PM	#6
silentassasin Major Drives: '07 BMW E90 Join Date: Dec 2010 Location: Orange County, CA Posts: 1,010 iTrader: (0)	The Obsession of making the ultimate driving machine __________________

08-25-2011, 03:07 PM	#10
kmarei Major General Drives: 1988 M3 Evo II Join Date: Jul 2008 Location: Reston, VA Posts: 6,043 iTrader: (32)	all that work for a $2000 part impressive __________________ "There are two opinions in this world. Mine and the wrong one." -- Jeremy Clarkson

08-25-2011, 11:37 AM	#4
rbrown81 Private Drives: 2009 E92 M3 Coupe Join Date: Jul 2011 Location: Atlantic City, NJ Posts: 86 iTrader: (0)	Wow.

08-25-2011, 12:08 PM	#5
E90 ME Private First Class Drives: 08 E90 335i Join Date: Jun 2011 Location: Johns Creek, GA Posts: 132 iTrader: (3)	Only BMW!

08-25-2011, 01:27 PM	#8
Voice of reason New Member Drives: BMW M Coupe Join Date: Jul 2011 Location: South Africa Posts: 26 iTrader: (0)	Challenge to BMW M: Next M3- As much as possible CFRP parts, not so much of price increase- please!!

08-25-2011, 04:40 PM	#11
James T. Kirk Captain of the Enterprise Drives: 2011 1 Series M Coupe Join Date: Nov 2010 Location: Alpha Quadrant, Sector 001 Posts: 1,407 iTrader: (0)	^ I know really. I'll never look at a CF part the same again. __________________ 2011 1 Series M Coupe VO M3 vs 1M Comparo Review 2011 M3 E90 DCT ZCP (sold) * 2010 335i Sedan (sold) 2005 M3 Convertible (sold) * 2003 325i Sedan (sold)

08-25-2011, 04:56 PM	#12
fdriller9 Banned Drives: '06 AW 330xi Join Date: Mar 2009 Location: North Jersey/Philly/NYC Posts: 7,092 iTrader: (4) Garage List 2006 330xi [3.22]	omg omg omg omg omg omg omg omg omg omg omg omg omgomg omgomg omg

08-25-2011, 05:14 PM	#13
IancoleTX Dillo boxers Drives: BMW Join Date: Jan 2010 Location: USA Posts: 2,872 iTrader: (12)	That is really damned cool. I would love to work for BMW __________________ 2011 135i 6MT - Alpine White / Savannah Beige

08-25-2011, 05:45 PM	#14
xerox445 Damenslip-Tropfer Drives: 2008 SGM 135i Join Date: May 2011 Location: LBI, NJ Posts: 544 iTrader: (1)	icarbon plant:

08-25-2011, 07:55 PM	#16
SilverII Colonel Drives: '11 335IS Join Date: Jun 2010 Location: DFW Posts: 2,319 iTrader: (0) Garage List 2011 BMW 335IS [4.83]	nice

08-26-2011, 11:35 AM	#18
DriveHard Lieutenant Colonel Drives: 128i M-Sport Join Date: Aug 2010 Location: Long Island Posts: 1,917 iTrader: (0)	Its amazing how clean quiet organized all those factories are... sad thing if you noticed....... not too many people working around all that machinery. __________________ '11 128i M-Sport Pkg, Sport Susp., 6AT w/paddles, BMW Perf CAI,Charcoal Filter Delete, BMW Perf. Big Brake Kit, BMW Perf. Exhaust, Ferodo 2500's, Titanium shims,135 trunk lip, BMS-PBX Box-Map 3, Castrol RBF600 ,e93 FSB, , f30 Backing Plates,GC Camber Plates, Hankook RS-3's (Track setup)

08-27-2011, 04:24 AM	#19
anerbe Major Drives: 335i Sedan Join Date: Dec 2006 Location: RO, MI Posts: 1,231 iTrader: (1)	^ yeah, it is sad, but the best quality control is to avoid manual labor as much as possible. I've worked with many plants for two different German companies in the US. The production process for serial production is often robust. Often times its the manual labor process that causes the variation in production or improper handling of suspect material. The only reason more manuacturing is not incorporating such automated processes is due to the high initial capital investments.

08-27-2011, 08:29 AM	#20
CJ421 Colonel Drives: 2011 E92 335i 6MT Join Date: Feb 2011 Location: PA Posts: 2,906 iTrader: (1) Garage List 2011 BMW 335i [4.63]	Incredible work. I ordered a BMW CF Performance Front Spoiler (goes under the bumper, very subtle) a few weeks ago, it was expensive and I can see why. __________________ 2011 BMW 335i - 6MT, M Sport, Le Mans blue, Logic7

08-27-2011, 02:22 PM	#21
Eeighty8 Enlisted Member Drives: 2010 E88 Join Date: Feb 2011 Location: chicago Posts: 42 iTrader: (2)	Few interesting points come to mind after watching that. 1. Quality. By moving all the carbon production in-house, they are controlling the quality. They obviously learned from Boeing's mistake of farming out carbon production all over the world for the 787 components. 2. Scale. They are fully committed to moving to composites for their city vehicles and ditching steel eventually. Composites have equal strength as steel, half the weight, and better energy absorption in a crash. I'm sure this is not an overnight process, but it looks like a substantial investment already. 3. Future vehicles. This much effort is not for making little spoilers and trim. All the rumors of the 3 and 4 cylinder motors - guess what cars they are going into? When your car now weighs 30-50% less, it will require a smaller engine. Smaller engine = less production costs. All that and better fuel economy with equal or similar performance. First the i3, etc., then next the MINI's I'm willing to bet. They are taking a big gamble and technological step forward. It will be interesting to see if/when it pays off.

08-28-2011, 02:07 PM	#22
the infamous... Lieutenant General Drives: like I'M BOUT THAT LIFE Join Date: Jul 2008 Location: PARADISE aka DAWNTOWN Posts: 16,890 iTrader: (0)	__________________ "simple is clean" -The ///ModFather [ iND ] - [ eAs ] - [ ACM ] - [ LTMW ] - [ AA ]

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