McLaren Automotive has once again pushed the boundaries of automotive engineering, unveiling a world-first application of aerospace-grade composite manufacturing for high-performance supercars. At the heart of this groundbreaking development is Automated Rapid Tape (ART), an advanced carbon fibre production method now deployed at the McLaren Composites Technology Centre (MCTC) in Sheffield, UK.
This innovative approach—adapted from aerospace manufacturing techniques—allows McLaren to create lighter, stiffer, and stronger carbon fibre structures while simultaneously reducing material waste. The first McLaren vehicle to feature ART carbon fibre is the upcoming McLaren W1, the latest entry in the brand’s revered ‘1’ series of Ultimate supercars. But this is just the beginning—future McLaren models will incorporate ART carbon fibre into their monocoques, redefining what’s possible in lightweight performance engineering.
Revolutionising Carbon Fibre Manufacturing
For over four decades, McLaren has been a pioneer in carbon fibre technology, first introducing it to Formula 1 in 1981 with the McLaren MP4/1 and later bringing it to road cars with the McLaren F1 in 1992. Today, every McLaren is built around a carbon fibre monocoque, delivering class-leading rigidity, safety, and weight efficiency.
The ART method builds on this legacy, drawing inspiration from aerospace manufacturing, where robotic arms lay down composite tapes to create high-strength structures for aircraft fuselages and wings. However, McLaren’s adaptation introduces a fixed deposition head and a rotating, high-speed bed, allowing for the rapid, high-rate production necessary for automotive applications. This results in:
- Greater structural optimisation – Engineers can fine-tune carbon fibre layups for targeted rigidity or flexibility.
- Superior strength-to-weight ratios – Fibres are concentrated in high-stress areas, eliminating unnecessary material.
- Reduced waste – Up to 95% of raw material is used, minimising off-cuts and inefficiencies.
- Consistent quality – Automated monitoring ensures each part meets exacting tolerances, reducing rejected components.
McLaren W1: The First Car to Feature ART Carbon Fibre
The first real-world application of McLaren’s ART carbon fibre will debut in the McLaren W1, an Ultimate Series hypercar designed for extreme aerodynamic efficiency and race-bred performance. The fixed plane within its active front wing assembly—a crucial component generating up to 1,000kg of downforce—is crafted using ART carbon, resulting in a 10% increase in stiffness over conventional pre-impregnated carbon fibre components.
Further ART carbon fibre elements are under consideration for production models of the W1, and McLaren has confirmed that future monocoques will integrate this cutting-edge technology, further enhancing structural rigidity and crash safety while keeping weight to an absolute minimum.
A New Era for McLaren’s Supercars
The benefits of ART carbon fibre extend beyond the monocoque, opening new possibilities for ultra-lightweight body panels and other structural components. With ART’s ability to significantly reduce production costs and lead times, McLaren now has the flexibility to integrate carbon fibre into even more areas of its vehicles.
As a next step, McLaren will scale up ART production, with a full industrial-spec machine set to be operational at MCTC by 2025. This marks a new chapter in McLaren’s relentless pursuit of performance without compromise, solidifying its position at the forefront of supercar innovation.
With the McLaren W1 leading the charge, the future of high-performance automotive engineering has never looked more exciting. The age of ART carbon fibre has begun.
