BMW to use carbon composites in electric vehicle

The greenfield factory will begin production in the third-quarter of 2011 and make ultra-lightweight carbon fibre reinforced plastics exclusively for BMW’s first vehicle under a new sub-brand. BMW calls the project a “megacity” vehicle. The automaker has not disclosed the sub-brand’s name or details about the vehicle other than to say it will be electric-powered and arrive before 2015.

The plant at Moses Lake in Washington will employ 80 and be built by the joint-venture partner, SGL Automotive Carbon Fibers.

Carbon fibre-reinforced plastics are currently used in limited parts on low-volume cars, but BMW will use the material throughout the structure and in exterior and interior body panels, said a BMW of North America spokesman.

Robert Koehler, CEO of Germany-based SGL Group, said in a statement that the new factory “will be the world’s most cost efficient carbon fibre plants using state-of-the-art technologies.”

SGL already has composite materials factories in the US and Canada making parts such as wind energy and aerospace components.

Friedrich Eichiner, member of the BMW AG board of management for finance, said that the two companies “will be able to produce carbon fibre enhanced components in large volumes at competitive costs for the first time.”

The new car will bring together global production sources beyond the new Washington site, with SGL and its Japanese joint-venture partner Mitsubishi Rayon creating part of the carbon fibre formula in Otake, Japan, as well as using BMW production in Landshut, Germany, and Wackersdorf, Germany.

BMW will also make the electric car at the same Leipzig, Germany, assembly plant that currently produced the 1 series passenger car and X1 crossover.

Plastics News Detroit-based staff reporter Rhoda Miel contributed to this story.