The ASCEND delegation. Source | GKN Aerospace

GKN Aerospace (Bristol, U.K.), in collaboration with McLaren Automotive (Woking, U.K.) and other U.K. partners, announces the successful completion of the ASCEND (Aerospace and Automotive Supply Chain Enabled Development) program. This 4-year, £39.6 million initiative has significantly advanced the U.K.’s high-rate composites manufacturing capabilities, focusing on high-rate production, Industry 4.0 and sustainable composite manufacturing.

The program, funded by a £20 million commitment from industry and a £19.6 million commitment from the UK government via ATI, aimed to accelerate the adoption of composites technologies, industrialize new technologies and meet future high-volume requirements. The collaboration brought together expertise from across the U.K. supply chain to develop advanced materials and automation equipment required for lightweight structures in the sustainable air mobility, aerospace and automotive industries.

Key achievements include:

Collaborative innovation. The program brought together 16 partners from the U.K.’s composites supply chain, each contributing their expertise to advance automation, material processing and tooling. GKN Aerospace led the consortium alongside Assyst Bullmer, Airborne, Cygnet Texkimp, Des Composites, FAR-UK Ltd., Hexcel Composites, Hive Composites, LMAT, Loop Technology, McLaren Automotive, the National Composites Centre (NCC), Rafinex, Sigmatex (UK) and Syensqo, with collaboration and investment support from Axillium Research.

Technological advancements. Significant progress was made in developing new methods, materials and processes, such as composite topology optimization with Rafinex, fast-cure prepreg technology systems from Hexcel and Syensqo, and joining mechanisms and cross sector bonding technologies with FAR-UK and Hive Composites.

Automation and digital integration. The development of automated systems from Loop Technology and GKN Aerospace’s RTM cell and Airborne’s automated ply placement (APP) technology showcased the potential for high-rate, high-quality composites manufacturing.

Sustainability. The NCC developed a Sustainability Maturity Level framework to assess and improve the environmental impact of composites manufacturing.

Demonstrator projects. The program’s success was highlighted by two flagship projects: GKN Aerospace’s bladed wingtip and McLaren’s rear floor component, both demonstrating the integration of aerospace precision with automotive production rates.

The consortium, led from GKN Aerospace’s £32-million Global Technology Centre (GTC) in Bristol, supported up to 130 jobs through 2023 and 2024. GKN Aerospace used its long-term experience and in-depth knowledge of composites engineering for integrated airframe structures throughout the project.

“Through ASCEND, we accelerated the development of next-generation lightweight, cost-effective, advanced composite technologies — critical for the aerospace and automotive industries in their transition to more energy-efficient aircraft and vehicles,” says John Pritchard, president civil airframe GKN Aerospace. “With the support of the Aerospace Technology Institute, which continues to play a vital role in advancing the U.K.’s position in next-generation aircraft, we have delivered key technological breakthroughs while achieving benchmark levels of price, quality and repeatability.”

The ASCEND program not only achieved its technological goals but also established a new paradigm for cross-sector collaboration, creating a robust supply chain and skilled workforce to support future innovations in composites manufacturing.