This technology aims to produce complex, high-stress composite parts at a sustained rate without compromising on quality. McLaren has entrusted Cygnet Texkimp, a specialist in fibre handling and processing, with the task of transforming the concept into a complete production machine.
This collaboration is rooted in the UK’s ASCEND programme, led by GKN Aerospace, which aims to strengthen the nation’s capacity to manufacture high-throughput composite components. The partnership has resulted in an automated and sustainable manufacturing solution, now integrated into the processes at the McLaren Composites Technology Centre (MCTC) in Sheffield, where it is already producing structural parts for the McLaren W1 Ultimate Supercar. A second industrial-specification ART machine is under construction at the Cygnet Texkimp innovation centre in Cheshire and will be delivered to McLaren in November 2025, marking a significant increase in capacity.
ART technology involves depositing dry carbon fibre tapes at speeds of up to 2.5 metres per second, while reducing waste to 95% of the material used in the final part. It is based on a fixed deposition head with a fast-moving work table, ensuring mechanical stability and high repeatability.
The system allows controlled fibre orientation to adjust stiffness and flexibility according to the requirements of the part. This structural tailoring paves the way for lightweight, rigid and aerodynamically active composite parts that meet the performance requirements of both the aerospace and automotive industries.
A strategic market opportunity
The exclusive licensing agreement between Cygnet Texkimp and McLaren Automotive now enables the British specialist to offer ART technology to other sectors such as aerospace, defence, energy and wind power. A full-scale demonstrator will be operational in early 2026 at Cygnet Texkimp’s innovation centre. Manufacturers will be able to test ART technology on their own materials and part geometries, with the support of the manufacturer’s R&D team, which already has production lines for carbon, thermoplastic and ceramic tapes.
“ART combines McLaren’s extensive knowledge and experience of highly specialised carbon fibre engineering with our world-leading fibre handling and processing expertise and understanding of mechanics and controls. The technology unlocks enormous potential for large-scale global markets to access the benefits of a highly specialised carbon fibre and composites manufacturing solution first developed for aerospace and high performance automotive-grade composites. It is relevant to many industries for the manufacture of composite structures that are optimised for superior performance,” concludes Luke Vardy, CEO of Cygnet Texkimp.
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