http://www.vwvortex....gets-green-light/
Future mobility is one of the most stimulating topics of our time. The key question here: By how much could the energy consumption of cars be reduced if all the stops were pulled out for efficiency? There is now an answer to this question from Volkswagen. It is the new XL1, with combined fuel consumption of 0.9 l/100 km. No other production car with a diesel plug-in hybrid is more fuel-efficient.
Lightweight construction (monocoque and add-on parts made of carbon fibre), very low aerodynamic drag (Cd 0.189) and a plug-in hybrid system - consisting of a two-cylinder TDI engine (35 kW / 48 PS), E-motor (20 kW / 27 PS), 7-speed dual-clutch transmission (DSG) and lithium-ion battery - enable a fuel consumption of 0.9 l/100 km, the new Volkswagen XL1 only emits 21 g/km CO2. Since it is designed as a plug-in hybrid, the XL1 can also be driven for up to 50 kilometers in pure electric mode, i.e. with zero emissions at point of use. The battery can be charged from a conventional household electric outlet. Naturally, battery regeneration is also employed to recover energy while slowing down and store as much of it as possible in the battery for re-use. In this case, the electric motor acts as an electric generator.
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THE XL1 Â MANUFACTURING
High-tech manufacturing: Body of new XL1 weighs just 230 kg / 507 lbs. Monocoque and exterior parts are produced from lightweight CFRP Volkswagen has set up handcrafting-like manufacturing for the XL1 in Osnabrück
The XL1 is a car of the future that is being built today. Not only are its technologies pioneering, but also the fact that Volkswagen is producing large parts of the XL1 in lightweight and strong carbon fibre reinforced polymer (CFRP). The monocoque with its slightly offset seats for driver and front passenger, all exterior body parts as well as functional elements such as the anti-roll bars are all made of CFRP. The preferred process for producing CFRP components at Volkswagen is the RTM process (Resin Transfer Moulding). The density of this material or its specific gravity is only around 20 per cent that of a comparable steel exterior skin. The CFRP parts exhibit a level of stiffness and strength that is by no means inferior to that of comparable steel or aluminium parts, yet the exterior skin of the XL1 is just 1.2 mm thick.
Innovative RTM process
Compared to other methods such as manufacturing CFRP in a prepreg process, CFRP production via RTM is more economical  with lower costs at higher part volumes  because it can be automated. The RTM parts are produced in multi-shell, heated and vacuum-sealed tools. This involves injecting liquid resin at high pressure into the tool containing the semi-finished carbon material whose interior has the shape of the part to be produced. The part cures afterwards in the mould.
Lots more at the linky.
It sounds neat, but it's not coming to the US anytime soon. And even with all the automation and efficiency, it's not cheap (Â50,000 lease only according to the comments, but pricing to be announced in the summer according to this review - http://www.autoblog....ive-review-video/ ).
FWIW.
Cheers,
Scott.