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Composites technology specialist Cygnet Texkimp (Northwich, U.K.), the designer and machine builder for global supercar manufacturer ’s (Woking, Surrey, U.K.) automated rapid tape (ART) technology concept, is now licensing the high-rate fiber deposition solution for multiple markets.

As part of a development program spearheaded by McLaren’s in-house innovation team, ART was designed to overcome the challenge of producing high-quality, complex, composites-intensive parts at viable rate and forms, including highly loaded and complex aerodynamic components, for McLaren’s supercar portfolio (learn more about the process here). Now, Cygnet Texkimp and McLaren have formed an exclusive licensing agreement that enables Cygnet to market the solution to other industries including aerospace, space, defense, wind energy and industrial as part of a long-term strategy to enable high-rate, sustainable manufacture of composites.

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McLaren commissioned Cygnet Texkimp to develop its technology into a full production-scale machine after the two companies took part in the ASCEND program (read “ASCEND program completion: Transforming the U.K.'s high-rate composites manufacturing capability”). A prototype high-rate deposition machine has been installed at the McLaren Composites Technology Centre (MCTC) in Sheffield. The technology is already integrated into McLaren’s manufacturing processes and is producing structural components for current supercar programs, including the McLaren W1 Ultimate Supercar.

A second industrial-specification ART machine, currently being built at Cygnet Texkimp’s Innovation Centre in Cheshire, will be installed at the MCTC in November 2025, delivering increased manufacturing capacity.

“ART combines McLaren’s extensive knowledge and experience of highly specialized carbon fiber engineering with our fiber handling and processing expertise and understanding of mechanics and controls,” says Luke Vardy, Cygnet Texkimp CEO. “The technology unlocks enormous potential for large-scale global markets to access the benefits of a highly specialized carbon fiber 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 optimized for high performance.”

ART manufactures high-performance carbon fiber composite parts at rate and with minimal scrap. Lengths of dry composite tape are laid down in rapid and accurate formation, at a speed of up to 2.5 meters/second, in a way that significantly reduces the potential for waste generated by off-cuts that cannot be reused. Up to 95% of the dry tape feedstock used to layer a component goes into the final part.

The solution creates new possibilities for innovation in automotive and aerospace engineering and design through its fiber placement capabilities. This element of the technology enables manufacturers to accurately tailor the load-bearing and stiffness characteristics of the finished part through the strategic positioning of the fibers. Specific adjustment of fiber orientation within the composite material allows for anisotropic stiffness: rigidity can be enhanced in specific directions while flexibility can be maintained elsewhere. 

The process has also been highly automated and digitized to offer extensive handling and real-time monitoring capability. In this way, end users are able to determine that every part has been manufactured to identical specifications, which in turn leads to significant time saving benefits linked to speed of manufacture and reduced test frequency.

A full-scale demonstration machine will be built at Cygnet Texkimp’s Innovation Centre where it will be available for customer trials in early 2026. Within the Centre, organizations will also benefit from Cygnet Texkimp’s tape manufacturing capability which includes advanced machines to manufacture dry carbon fiber tapes alongside high-performance thermoset, thermoplastic and ceramic prepreg materials.