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3 Kitted fabrics are preformed in a Fill Gesellschaft (Gurten, Austria) Preformliner press (see press photo on p. 28). Shown here is a part preform, fresh out of the press and ready for trimming and stapling. 2 Each i3 Life Module comprises 39 different stacked kits, which are used to make 49 preforms, which are then combined to produce 16 resin transfer molded parts. 8 Finished Life Modules are transferred from the Body Shop to fnal assembly. 6 Life Module assemblies are adhesively bonded in an entirely automated process. Here, three of the 173 ABB robots in the Body Shop put the fnishing touches on a bonded module. 7 The i3 roof features carbon fber recycled from scrap generated during Life Module processing. The stitched, nonwoven fabric allows BMW to give the car the highly prized "carbon fber look" and enhances the vehicle's sustainability. 1 In the CFRP Building, carbon fber fabrics for the life module (cut and kitted by BMW in Wackersdorf, Germany, then delivered to Leipzig) are sprayed with a thermoplastic binder. Source (all step photos) | BMW AG bordered on one side by four 2.5-MW wind turbines, which pro- vide some, but not all, of the power consumed by the facility. Te complex of buildings is dominated at its core by the structure that serves as the main entrance and architectural focal point — an imposing glass-and-concrete structure that conveys the moder- nity of the plant and the company. Inside is a three-story vaulted hall that is home to several functions presented in layers. Its re- ception area is backed by an elevated bank of desks, arrayed in cubicles and glassed-in ofces. Overhead is a conveyor system on which BMW's production bodies-in-white move through the hall from the adjacent assembly plant on their way to paint booths elsewhere. Tis striking feature, visitors are told, is intended as a continual reminder to the plant's employees of the importance and immediacy of the job at hand — making cars. Six of the 10 buildings at BMW Leipzig are devoted to manufac- ture and assembly of standard (gas-powered) BMW models, includ- ing the X1, the 1 series (5-door) and the 2 series (coupe). Buildings 7 through 10, however, are devoted to BMW's i-series vehicles. BMW reportedly invested €400 million ($597 million) in these manufac- turing facilities, which turn out the i3 and the hybrid-electric i8 sports car, due out late this year. MOLDING THE MODULE Te i3 Life Module, in its fnished form, looks like a basic body- in-white car frame, but comprises several carbon fber composite components that are adhesively bonded. Its components take shape in what BMW calls the CFRP Building. Te kitted carbon fber fabrics, produced in Wackersdorf, are delivered here for 2 6 C O M P O S I T E S W O R L D . C O M INSIDE MANUFACTURING 0614CT IM-OK.indd 26 5/20/14 1:38 PM