CARBON FIBRE FOR ALL
High-tech materials are coming to your bike
Carbon components might sound like the preserve of MotoGP but the black weave has been slowly creeping onto production bikes for the last three decades and this prototype carbon fibre swingarm for BMW’s F800R proves that we’ll soon see it on mainstream machines. When BMW released the HP4 RACE in 2017, it boasted an embarrassment of resin transfer moulded carbon indulgence. But now BMW have perfected a new method of complex structural production that could see major carbon fibre components used on affordable road bikes.
The big breakthrough
Working with seven industrial partners, including the German government, BMW have made a breakthrough in more cost-effective volume-production of carbon fibre reinforced plastic.
“We opted for chassis components under continuous load,” says Project Manager Elmar Jager. “The motorcycle swingarm was ideal for our project because the forces at work are immediately evident.” In standard carbon fibre construction, the fibres are woven into sheets and impregnated with resin. These sheets are then handlaid into moulds to build up layers, which is time consuming and expensive. The new production technique uses high-strength endless fibres in high stress areas, alongside short recycling fibres in low stress areas. The result is a process that can be mechanised, meaning a single machine can produce a range of injection moulded carbon reinforced plastic composite parts (CFP) in minutes, not hours.
So what next?
“When it comes to emissions and economy you need to have the bikes light and strong. Carbon is the best way,” says HP4 RACE Project Leader Christian Gonschor. “From a technical point of view, it’s the perfect material to play with.” Dr Joachim Starke, head of carbon fibre research and development, added: “The insights gained in the use of CFP in serial production will boost the future development of new BMW motorcycles,” CFP will soon transform even the most affordable production bikes, making them lighter and more efficient, while also boosting performance.
‘The HP4 Race used BMW’s first carbon frame’