BMW Developing Carbon Fiber Components

The use of carbon fiber in vehicle applications is not a new concept, however the cost of manufacturing components made from carbon fiber is typically the limiting factor in its usage. Carbon fiber is a very strong, stiff, carbon based material that can be molded into complex shapes. Once carbon fiber is formed into its end shape, it is very lightweight and can surpass the strength to weight ratio of many competing metals, such as many grades of aluminum and steel. BMW has used carbon fiber in their vehicles and motorcycles throughout the years because it provides obvious engineering advantages for strength and weight, and it is also considered a premium material with a history of usage in motorsports racing. BMW recently ceased production of carbon fiber components for undisclosed reasons. This decision was met by the automotive industry as indicating that BMW’s carbon fiber production was not profitable. However, BMW insisted that carbon-based component production would continue through other avenues. One such avenue that was recently unveiled was the development of a carbon fiber reinforced plastic (CFRP) motorcycle swing arm. The swing arm was developed with seven joint partners as a demonstration of a new manufacturing process termed “resin transfer molding”. The swing arm is incredibly light and strong, and has won 2018 JEC Innovation Award for its production method and end result. BMW stated that they chose to model a swing arm using resin transfer molding to demonstrate the effectiveness of the technology on a part that sees continuous stress during normal usage. The motorcycle swing arm utilizes short carbon fibers in locations on the swing arm that require localized strength. For location of the swing arm that requires elongated stiffness, long fibers were incorporated into the mold.  According to BMW, the cost saving techniques that they learned from development of the swing arm will be directly attributable to other motorcycle components. In the future, BMW will also begin incorporating the same carbon fiber reinforcement for automotive applications.

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