BMW i3 Teardown and Benchmarking Report

  For its first teardown carried out without the involvement of an OEM, Munro & Associates analyzed a BMW i3 with a range extender. The company purchased the vehicle with its own funds and converted detailed analyses of roughly 65,000 components into data that for the vehicle as a whole fills around 54,000 pages. Each component’s costs (prices for standard components are estimated) are calculated, which is useful for cost reduction activities and design proposals.

Major Characteristics of the BMW i3

CFRP body structure CFRP body structure
The cabin space where passengers ride has been dubbed the life module. It is made of CFRP, which gives it extremely high body rigidity, dimensionally perfect build and impact safety performance, while also significantly reducing weight. These seemingly contrasting goals are achieved by forming the CFRP body with resin transfer molding, and applying thickness or shaping to individual areas as needed to gain the necessary strength.  All of the CFRP parts are joined through bonding, with those connections having a total length of up to 160 m.
Aluminum chassis frame Aluminum chassis frame
The aluminum frame, which is part of the drive module, is equipped with powertrain components including the drive motor and transmission; as well as parts like the battery, range extender (power generator) for the engine, large lithium-ion battery, and front and rear suspension. Moreover, the aluminum frame has been designed to weld die castings to aluminum extrusions to absorb impact during collisions in order to keep the CFRP cabin from deforming.
High-voltage battery High-voltage battery
The aluminum battery case is fitted with 8 lithium-ion battery modules and positioned below the cabin floor. Positioning the batteries in this manner lowers the center of gravity of the vehicle and increases body rigidity. The battery case is equipped with a battery cooling system that uses AC refrigerant and an electric heater to handle hot and cold weather conditions.
EV powertrain system

EV powertrain system
The driver motor has an output of 125 kW and maximum torque of 250 NM. The BMW can accelerate from 0-100km/h in 7.3 seconds and activated a speed limiter when it achieves its maximum speed of 150km/h. Vehicles equipped with a range extender have a 2-cylinder 647 cc engine for electric generation that has an output of 28 kW.

Environmentally friendly materials for the interior Environmentally friendly materials for the interior
Of the plastic used for the BMW i3’s interior, 25% (weight ratio) is recycled or recyclable material. Recycled PET bottles are just one of the materials used to make the seats to consist of 100% recycled materials. The dashboard and door panels partially adopt Kenaf fiber. Natural DECCAN hemp fiber is available for door trims as an option.

Sales units, Pricing

  (1) The vehicle as a whole (54,000 pages) : 4,200,000 JPY
  (2) By component (65,000 components):

  * 1. Extracting specific material types such as resins or aluminum, or particular components like ECU`s or sensors is possible.
    Reports include by-component material information, manufacturing methods used, tons of mold press force, and estimated costs.

  * 2. We are taking orders for teardown analyses of vehicles other than the BMW i3. Please contact us for more information.

Zone Main components Price (JPY)
Zone 1: Body Life Module (= Upper Body), Door and Closures, Latches, Seals / Adhesives / Chemicals 1,300,000
Zone 2:  Exterior Rear Quarter Panels,  Fascias, Badging,Fenders,  Door Exterior Windowshield / Wipers,  Head Lamp / Tail Lamp/ Fog Lamp,  CHMSL (Center High Mounted Stop Lamp ) 700,000
Zone 3:  Chassis Chassis Frame, Suspension,  Brakes,   Elect. Parking Brake,   Brake Lines,   Elect. Pwr Steering,  Wheels & Tires,  Sealant Kit / Pump 1,050,000
Zone 4:  Battery System Battery Pack,  DC / DC Converter, Power Module, 12V Battery, Battery Harness, Charger 1,500,000
Zone 5: Electronics System Electronics,  Infortainment,  Body Control Module, Fuse Box 1,050,000
Zone 6:  Cooling Pack& HVAC Cooling( Battery / Engine), Radiator, HVAC,  Evap.  Condenser,Compressor 600,000
Zone 7: Driveline Driveline, Motor, Gear Box, Half Shaft 700,000
Zone 8:  Range Extender System Range Extender System, Engine, Generator, Fuel and Tank, Exhaust/Shields, Engine Dress & Harness, Electric Control Unit 1,200,000
Zone 9:  IP(Instrument Panel) & Interior Trim IP and Harness, Cross Car Beam, Floor Console / Shifter, Door Trim, Headliner, Carpet / Mats, Trunk Trim, Pedal Box, Steering Wheel 1,100,000
Zone 10:  Seats Seats, Seatbelt, Air Bag, Safety 800,000



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