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McLaren ART Carbon: A Revolutionary Aerospace-Grade Carbon Fibre For Supercars
McLaren Automotive has pioneered a unique application of aerospace composites manufacturing for supercar production. This innovation, implemented at the McLaren Composites Technology Centre (MCTC) in Sheffield, UK, uses the Automated Rapid Tape (ART) method. This technique creates McLaren ART carbon fibre structures that are lighter and stronger with less waste. The fixed plane in the new McLaren W1's front wing assembly is made using this advanced method.
McLaren's extensive experience with carbon fibre spans over four decades. This expertise has been crucial in both racing and automotive applications, making carbon fibre a standard in Formula 1 and road cars. Every McLaren car features a carbon fibre monocoque, maximising performance through lightweight and durable materials.
The aerospace industry employs precise methods to craft tailored carbon fibre structures for aircraft. These methods involve robotic tape deposition instead of traditional hand layup techniques. McLaren has adapted a rapid version of this process for its manufacturing at MCTC, enhancing its cars with optimised carbon fibre structures.
The ART method revolutionises aerospace techniques by using a machine with a fixed deposition head and rotating bed. This allows faster production suitable for automotive needs. Engineers gain design freedom as ART enables tailored fibre placement, allowing specific adjustments for load-bearing or stiffness requirements.
ART technology allows engineers to innovate without uniform material constraints. Fibre orientation can be adjusted within the composite material to enhance rigidity in specific directions while maintaining flexibility elsewhere. This opens up new design possibilities for complex aerodynamic components.
By concentrating fibres in high-stress areas like joints or edges, unnecessary material can be removed from low-stress regions. This optimises strength-to-weight ratios and reduces waste during production.
Reduced Waste Production
The ART process significantly cuts down on waste by using measured lengths of dry composite tape, reducing irregular off-cuts. Up to 95% of raw tape material is used in final parts, minimising human error and ensuring consistent quality within design tolerances.
This automated process provides real-time monitoring and control, ensuring optimal part quality and reducing rejected parts due to inaccuracies.
Future Applications
The benefits of ART technology include reduced manufacturing time and costs, enabling broader use of carbon fibre across vehicles. Beyond the carbon tub, ultra-lightweight body panels made from McLaren ART carbon fibre become more feasible and cost-effective.
A prototype high-rate deposition machine is already installed at MCTC, with plans to upscale it to an industrial-spec machine by 2025. The first vehicle featuring ART carbon fibre is the new McLaren W1 supercar.
Next-Generation Carbon Fibre Structures
The fixed plane within the W1's active front wing assembly benefits from increased stiffness due to ART technology. This component is up to 10% stiffer than comparable pre-impregnated parts, enhancing its aerodynamic load-bearing function.
Further components made from ART carbon fibre are being considered for future W1 production models. The potential for next-generation carbon fibre architectures is immense, integrating this technology into ultra-lightweight tubs with minimal waste generation.
McLaren Automotive continues to push boundaries in supercar production through innovative partnerships and technological advancements. The company remains committed to creating exhilarating vehicles that set benchmarks in performance and design excellence worldwide.
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