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McLaren Develops AeroSpace Grade ART Carbon Fibre For Manufacturing Supercar
McLaren has developed a new carbon fiber manufacturing process called Automated Rapid Tape (ART) carbon, adapting an aerospace industry technique for use in supercars. This process automates the deposition of dry composite tape, allowing precise fiber placement and optimizing the strength-to-weight ratio. The ART carbon process increases material efficiency and reduces waste. The first vehicle to feature ART carbon fiber is the McLaren W1, and McLaren plans to expand the use of this technology in future supercars.
Atul Bandhu
Updated Mar 7, 2025, 04:11 PM IST
McLaren Develops AeroSpace Grade ART Carbon Fibre For Manufacturing Supercar
McLaren Automotive has developed a new carbon fibre manufacturing process, Automated Rapid Tape (ART) carbon, adapting an aerospace industry technique for use in supercars. The innovation, implemented at the McLaren Composites Technology Centre (MCTC) in Sheffield, UK, aims to enhance structural efficiency, reduce material waste, and improve performance.
Aerospace-Derived Manufacturing Process
The ART method automates the deposition of dry composite tape using a fixed deposition head and a rotating bed. Unlike traditional hand-laid carbon fibre, this approach allows precise fibre placement, enabling engineers to adjust stiffness and flexibility in different areas of a component. The process is designed to optimise the strength-to-weight ratio while minimising excess material.
Material Efficiency and Waste Reduction
The ART carbon process increases material efficiency, with up to 95% of the dry composite tape incorporated into the final product. This automated system also reduces human error in material placement, ensuring consistency and quality. By concentrating fibres in high-stress areas and minimising material in low-stress regions, ART enables more efficient use of carbon fibre in vehicle production.
First Application in McLaren W1 Supercar
The first vehicle to feature ART carbon fibre is the McLaren W1, part of the company’s Ultimate Series. The fixed plane within its active front wing assembly is manufactured using this technology, resulting in a 10% increase in stiffness compared to conventional pre-impregnated carbon fibre parts. Additional components using ART carbon are being considered for the W1’s production version.
Future Implementation
McLaren has installed a prototype ART carbon fibre machine at MCTC, with plans to introduce an industrial-scale version in 2025. The company is exploring broader applications of this technology, including potential use in future supercar chassis structures and lightweight body panels.
By adapting aerospace-grade manufacturing techniques, McLaren aims to expand the use of carbon fibre in its vehicles, optimising performance while reducing production waste and costs.
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