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Shape Machining Ltd. (Witney, UK) has produced 
tools and made composite parts for the new
 Elemental RP1 high-performance sports car, from Elemental Motor Co. Ltd. (Waterlooville, Hants,
UK). Designed and manufactured by a team of ex-McLaren designers, the recently launched RP1 features advanced aerodynamics and novel composite solutions, including an all-carbon composite passenger tub built to Formula 1 strength and stiffness standards. The result, according to Shape, is a stunning, modern, high-performance road car.

“The performance of the RP1 is amazing,” claims Shape’s managing director, Peter McCool, noting a 0-60 mph time of less than 3 seconds during testing. “As you can imagine, we are very pleased that Shape has supplied tooling and parts to this beautiful new sports car. Our engineering background and willingness to undertake R&D work allows us to develop innovative solutions to meet specific customer requirements. Elemental have benefited from this approach.”

Shape was founded by McCool, a former F1 designer, to provide precision-machined composite tooling to the motorsport, automotive and aerospace industries, where complex composite tooling is a requirement. The company recently launched the Shape Tex brand of composite preform manufacturing. Dry carbon/glass preforms are intended 
for use in resin infusion and resin transfer molding (RTM) processes. Shape also produces thermoplastic preforms using SYNERGEX commingled carbon/thermoplastic fibers, a technology provided by Coats Group (Uxbridge, UK).

Peter Kent, composites director, Elemental Cars, says, “The RP1’s weight is crucial to its performance, and we are using 21st Century materials and manufacturing processes to make a car that is fast, strong and light. Shape’s expertise
in creating the specialized tooling for some of the advanced composite parts on the RP1 has helped us to achieve our specific brief of engineering a lightweight sports car that delivers unrivalled performance and driver engagement.”

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