Improved aerodynamics and weight-saving for BMW M3

The BMW M3 was shown at the Auto Expo 2008 held in Delhi re-cently. The car is a CBU and is offered in India as part of the M family. The M3 is a high performance version of the popular compact BMW 3-Series automobile. Common upgrades over the "standard" 3-Series automobiles include larger and more powerful engines, improved handling/suspension, more aggressive bumpers/body, and an interior accented with "M" nomenclature. 

The most recent in the long living line-up of M3s is the E92, which was launched at the fag end of 2007 in Europe. The E92 M3 is powered by the S65, a 4.0 L V8 engine mated to a six-speed manual tranny. While an all-new double-clutch 7-speed gearbox is expected in the later part of 2008, the E92 M3 may resemble the one it replaces but flaunts body panels that are arguably unique to the M3. 

Dietfurt, Germany-based supplier to M3, Takeo GmbH Automotive Systems is supplying underbody shields to the new M3. Employing SymaLite from Quadrant Plastic Composites, which was recently upgraded to deliver improved mechanical and acoustical properties, the underbody shields are actually lightweight panels that cover almost the entire underside of the car, offering optimised aerodynamics for improved vehicle handling and fuel efficiency. According to Karl-Heinz Kalmbach, Leader-Business Line Exterior and Structures, Quadrant Plastics Composites: "SymaLite technology allows for physical and mechanical properties to match the demands of the part by varying the mix of PP and glass fibres. This offers a new level of design and processing flexibility. For example, it accommodates flat part design without the corrugations usual to parts moulded in GMT and LFT, thereby giving better aerodynamics and acoustics damping characteristics." 

 SymaLite is an intelligent light weight composite material based on polypropylene (PP) and specially orientated glass fibres, which set new standards for the weight, rigidity and shape. Uniquely the pre-orientated fibres of SymaLite allow good loft behaviour during the heating and moulding process, giving expansion of up to six times its original thickness and achieving densities of only 0.3g/cm3, while increasing bending stiffness in the z-direction. 

The new BMW application for which SymaLite is specified includes engine shield, gearbox shield, under body shields to which it brings significant weight savings, improved acoustical performance, better aerodynamics, corrosion resistance and safety due to the material's high resistance to crack propagation and deformation. In supporting these applications, Quadrant Plastics Composites has been working in close co-operation with the German Tier One supplier, Takeo. This includes providing design support, material recommendations, tool development, processing line lay-out, developing new material grades based on the specifications of the OEM.