ASCEND program completion: Transforming the U.K.'s high-rate composites manufacturing capability
GKN Aerospace, McLaren Automotive and U.K. partners chart the final chapter of the 4-year, £39.6 million ASCEND program, which accomplished significant progress in high-rate production, Industry 4.0 and sustainable composites manufacturing.
GKN’s advanced automated preforming technology cell (ADAPT) and smaRTM Cell work together to significantly reduce touch labor and overall cycle time while ensuring a high-quality and repeatable process for integrated resin transfer molded (RTM) structures. Source | GKN Aerospace
What started as a conversation between GKN Aerospace’s (Bristol, U.K.) technology director Craig Carr and McLaren Automotive (Woking, U.K.) in 2019 sparked what would become one of the U.K.’s most ambitious cross-sector composites manufacturing initiatives. The discussion centered on a striking observation: McLaren’s Sheffield-based Composites Technology Centre (MCTC) was developing highly automated manufacturing processes that, while considered “low-rate” by automotive standards, represented high-rate production in the world of composites.
This realization led to a compelling question: Could aerospace and automotive sectors learn from each other to accelerate composites manufacturing to new levels? This initial dialogue eventually evolved into what would become the ASCEND (Aerospace and Automotive Supply Chain Enabled Development) program — a major collaborative effort in the U.K. composites industry to improve high-rate production, Industry 4.0 and sustainable composites manufacturing. GKN Aerospace led the technical aspects of this program from its Global Technology Centre (GTC) in Bristol, while Axillium Research (London, U.K.) provided management expertise, bringing together 15 partners from across the U.K.’s composites supply chain.
The initiative kicked off in early 2021 as a 4-year-long program, with a substantial financial foundation of £39.6 million — £19.6 million in government support through Innovate UK and the Aerospace Technology Institute, matched by £20 million in contributions from industry partners. By the program’s conclusion in March 2025, it had successfully completed 17 work packages and achieved technology readiness level (TRL) 6 across 42 individual projects, demonstrating significant technological advancement in the composites field.
Carr from GKN looks back at the program’s impact from an aerospace company’s perspective. “ASCEND was a significant accelerator for what we identified as opportunities for technology exploitation. It led to significant improvements in our composites manufacturing capability. The collaboration showed technical synergies between aerospace and automotive that we could never have fully anticipated until this program.”
The program’s structure, developed through extensive workshops and industry consultations, encompassed five key themes.
McLaren drove the automotive side of the program, targeting improved composite accuracy and properties at rate for its road cars. Joseph Elford, plant director at the MCTC, describes the outcomes for the sports car manufacturer: “MCTC’s engagement with ASCEND has been about transforming complex designs, traditionally achievable only in low-volume scenarios, into high-volume, scalable production methods. We’ve focused on bridging the divide between aerospace and automotive sectors, taking established aerospace technologies like tape deposition and adapting them for automotive rates. This has allowed us to optimize fiber architecture and topology while maintaining the high throughput demands of road car production. The knowledge exchange with the aerospace sector has been invaluable, challenging our approaches and leading to innovations in automation and material science that benefit both industries.”
The evolution of ASCEND
The ASCEND consortium was carefully orchestrated by Axillium Research to identify and unite complementary capabilities. Each U.K. partner brought unique expertise: Assyst Bullmer (Wakefield) and Loop Technology (Dorcheshire) in automation systems; Cygnet Texkimp (Cheshire) and Sigmatex (Cheshire) in material processing; Hexcel Composites (Cambridge), Syensqo Composite Materials (previously Solvay, Heanor) and Hive Composites (Leicestershire) in advanced materials development; LMAT (Bristol) and FAR-UK (Nottingham) in tooling and manufacturing processes; Des Composites (Sheffield) in design, testing and simulation; Rafinex (London) in optimization software; Airborne (Lambourn) in automated manufacturing cells; and the National Composites Centre (NCC, Bristol) providing research and sustainability framework development.
The program’s structure, developed through extensive workshops and industry consultations, encompassed five key themes: lightweight design tools, future material systems, rate-capable automation, electrification and multifunctional capabilities, and integrated hybrid structures.
“By integrating automotive’s upfront digital and virtual engineering approaches with aerospace’s rigorous certification protocols, we established new paradigms for high-rate composites manufacturing,” Will Searle, Axillium’s chairman, remarks. “The program demonstrated that TRL can be approached differently across sectors — where aerospace TRL 6 represents critical investment thresholds, automotive development can iterate rapidly through multiple design cycles. This cross-pollination enabled us to develop industry-agnostic manufacturing capabilities that can scale from 3-foot UAV components to 3-meter aircraft structures. Our virtual technical review meetings and integration workshops also fostered an environment where small, specialized R&D teams could collaborate effectively, even during lockdown restrictions, leading to breakthrough advances in areas like physics-based digital twinning and optimization of material systems for rate-capable automation.”
Composite material, tooling technology development
Several materials technologies and processing innovations were developed by the ASCEND partners.
Hexcel
HexPly M51 system achieves 40-minute cure cycles of a wing tip without post-cure requirements while maintaining aerospace mechanical specifications. Source | Hexel
At the heart of improving composites quality at high-rate, Hexcel developed HexPly M51, a fast-cure prepreg system capable of achieving full cure in 40 minutes without post-cure requirements. Validated through extensive trials within the ASCEND project, HexPly M51 demonstrated mechanical properties comparable to traditional aerospace-grade materials while matching automotive production speeds.
“Our success depended on integrating sophisticated processing models — combining kinetic thermal profiling with viscosity analysis — which proved crucial for understanding material flow and preventing void formation,” explains Lee Allgood, Hexcel Composites program manager. “The development leveraged our expertise in formulation chemistry to create a robust prepreg system capable of both autoclave and press processing while achieving hot-load processing efficiency.
“We validated the material’s versatility and high-rate processing through the manufacture of parts with complex geometries and automation trials at various scales, ranging from 6.35-millimeter automated fiber placement [AFP] to 300-millimeter-wide tape laying [ATL], as well as automated pick-and-place trials in partnership with Airborne,” Allgood adds. “Within the project we also implemented digital twinning solutions with finite element analysis [FEA] simulation models for optimal material use in partnership with LMAT. The resulting product not only matches the mechanical performance of aerospace standards like HexPly M21 and HexPly 8552 but achieves this with a reduced total cure cycle of 40 minutes at elevated temperatures, representing a significant advancement in processing efficiency.” Following its development in this project, the HexPly M51 system is now available in both unidirectional (UD) HexTow IM5-24K and IM9-24K carbon fiber as well as woven glass and carbon PrimeTex (spread tow products).
Syensqo
Syensqo contributed to ASCEND’s material advancement through its Cycom EP2750 fast-cure technology platform, which represents a crucial step toward achieving automotive-like production speeds while maintaining aerospace quality standards. The material system combines continuous fiber prepreg capabilities with sophisticated process control, enabling complex geometries to be manufactured with a 30-minute takt time — a dramatic improvement over traditional aerospace composites processing time, according to Dr. Luca Restuccia, Syensqo’s aerospace and defense product development leader.
“Cycom EP2750 reduces production times by a factor of 10 to 20 compared to traditional aerocomposites processes,” says Restuccia. “The material’s compatibility with processing technologies like double diaphragm forming and spring frame press fabrication enables us to achieve these improvements throughput. By combining faster processing with hot compression molding techniques, we’re able to reduce the cost per part, particularly for smaller components. This makes composites genuinely competitive with traditional machined aluminum while maintaining the high-performance requirements of aerospace applications. The system’s versatility across both primary and secondary structures, coupled with its enhanced notched compression properties, positions it perfectly for high-rate commercial aircraft programs as well as military and air mobility platforms.”
Sigmatex
Sigmatex focused on developing specialized tapes for McLaren’s high-rate deposition technology, addressing the limited capacity of traditional tape bobbins that necessitated frequent production stops. The company’s research led to new winding formats that could potentially reduce downtime by one-third, while simultaneously tackling the complex challenge of maintaining aerospace-grade quality at automotive production speeds.
Advanced carbon fiber tape architecture integrates real-time quality verification for aerospace-grade specification at automotive rates. Source | Sigmatex
“In developing high-performance, highly aligned carbon fiber tapes, we encountered a fundamental challenge: The dense fiber arrangement that provides exceptional mechanical properties also creates a barrier to resin penetration,” Bryony Pigram, lead textile development engineer at Sigmatex, explains. “Our research led us to optimize both the carbon fiber sizing and UD architecture to achieve infusion rates comparable to traditional noncrimp fabric [NCF] and woven fabrics while maintaining structural integrity. This optimization, coupled with our automated quality monitoring systems, has enabled us to meet aerospace-grade specifications at automotive production speeds. The integration of digital passporting and real-time quality verification has also transformed how we validate material performance, moving from manual inspections to data-driven quality assurance that can keep pace with high-throughput manufacturing demands.”
FAR-UK
Robotic adhesive dispensing system with laser scanning enables topology-optimized bondlines on complex geometries. Source | FAR-UK
FAR-UK’s contributions centered on developing an iterative optimization process for composite structures, integrating environmental analysis with advanced manufacturing techniques. The company’s work combined material selection, topology optimization and environmental impact assessment into a cohesive framework to achieve more sustainable manufacturing capabilities. A key innovation in ASCEND was FAR-UK’s collaborative robot (cobot) system for bonding, featuring laser scanning capability and edge detection for precise adhesive application on complex geometries.
“What sets our process apart is the seamless integration between our computational design and physical manufacturing capabilities,” Helena Job O'Connell, FAR-UK sustainability engineer, says. “We’ve developed a sophisticated FEA analysis framework that works in tandem with Rafinex software for topology optimization, allowing us to precisely determine optimal adhesive pathways based on specific loading conditions. Our cobots take this theoretical optimization and translate it into physical reality — they’re equipped with laser scanning and edge detection that enables automatic offset dispensing, meaning we can maintain uniform adhesive application on complex geometries.”
FAR-UK demonstrated this technology in its automotive footwell tool project, where its team first computationally optimized the adhesive placement for torsional and longitudinal loads, validated it through FEA and then achieved precise jig-less bonding with controlled bead thickness.
Cygnet Texkimp
S-wrap configured Multi Roll Stack doubles production rates while reducing energy consumption 50% through vertical roller integration. Source | Cygnet Texkimp
Cygnet Texkimp developed three systems within the program: an automated filament winding cell at rate, a Multi Roll Stack machine and a thermoplastic prepreg machine to deliver material for the automated winding cell.
What was the goal? The Multi Roll Stack’s S-wrap configuration achieved a 50% reduction in energy consumption compared to traditional composite material handling technology while maintaining consistent temperature throughout the manufacturing process. This advancement proved particularly crucial for producing materials suitable for Type 5 hydrogen storage tanks, a key focus of the program’s wider sustainability initiatives.
“The Multi Roll Stack’s S-wrap architecture represents a fundamental shift in prepreg processing, achieving 10 meters per minute production speeds at 112 grams per square meter coat weight — double the traditional rate for aerospace-grade materials,” details Luke Vardy, managing director of Cygnet Texkimp. “By vertically integrating multiple impregnation rollers in a single compaction module, we’ve eliminated the heating/cooling cycles typical of inline prepreg technologies while enabling precise tension governance through speed-controlled induction motors. This configuration is particularly crucial for Type 5 hydrogen tank manufacturing, where consistent resin distribution and fiber orientation are essential for containing hydrogen molecules with their 2.89 Ångström kinetic diameter under extreme pressures. The system’s ability to automatically manipulate fabric weave during processing optimizes both draping characteristics and interlaminar shear strength, also critical properties for high-performance, filament-wound composites operating at pressures up to 1,000 bar.”
LMAT
LMAT focused on addressing assembly challenges through innovative tooling solutions. Accordingly, its self-heated tooling system ensures uniform temperature distribution during composite curing while enabling demolding without mechanical aids. Integration of zero-cavity bladders and precise monitoring systems added to ASCEND’s tooling technology improvements, notably demonstrated in manufacturing one of McLaren’s rear spoilers. LMAT’s technical director, Tomasz Garstka explains: “Our resistive heating technology achieves thermal uniformity within ±4°C through optimized spacing of electrical elements laminated directly into the mold structure. When combined with our zero-cavity bladder system, which provides precise 2-millimeter component elevation for demolding, and our thermal-based monitoring system capable of detecting flow fronts in carbon fiber laminates — something conventional imaging techniques cannot achieve — we’ve created a comprehensive solution that transforms how we approach composites manufacturing.”
Self-heated composite tooling achieves ±4°C thermal uniformity with integrated zero-cavity bladders for demolding. Source | LMAT
Hive Composites
Advanced thermal management has been complemented by Hive Composites’ development of novel bonding processes. The company’s director Peter Hansen says embedding heating elements within the bonded parts themselves has optimized how large composite structures are assembled. The developed process integrates a conductive layer along the bondline of the laminate structure, enabling the application of electrical currents for localized heating at the adhesive interface. By embedding these heating elements within the bonded parts themselves, Hive can heat only the bond area rather than requiring large ovens for entire assemblies.
Conductive bondline technology enables localized electrical heating, eliminating ovens while enhancing joint performance. Source | Hive Composites
“Our testing demonstrates enhanced bond strength when heating the adhesive interface directly versus traditional through-thickness heating methods,” Hansen says. “The system also enables precise temperature control during assembly, with higher current applications capable of softening the adhesive for controlled component separation when needed. This configuration allows for concurrent operations during the curing process, such as trimming and drilling, while maintaining the mechanical integrity of the bond area. The direct interface heating method has shown significant reductions in energy consumption compared to conventional oven-based bonding techniques.”
To complement LMAT’s self-heated tooling method, Hive Composites developed a novel tooling system that embedded a carbon nanotube (CNT)-based material as a heating element in CFRP and GFRP mold tools. The system demonstrated a significant reduction in cure times and reduced energy requirements by 90% compared to autoclave cure, potentially eliminating the need for ovens or autoclaves. Thermal mapping of the tool face was also demonstrated with ±2°C accuracy.
Automation systems for composites manufacturing
Various automation solutions were developed for ASCEND including novel approaches for material handling to process monitoring.
GKN Aerospace
At GKN Aerospace’s GTC in Bristol, an automated resin transfer molding (RTM) cell showcases ASCEND’s advancements in automated preforming, intelligent process monitoring and optimized material handling.
“Through ASCEND we’ve developed an integrated manufacturing ecosystem that transforms how we produce composite structures,” Tony Lloyd, GKN principal composite research engineer, explains. “Our automated RTM cell combines custom injection equipment with smart tooling and induction heating, all orchestrated through a digital twin framework. This allows us to achieve aerospace-grade quality at automotive-inspired production rates.”
According to Lloyd, GKN’s breakthrough is how the company merged rapid press forming of thermoset materials with automated handling — enabling component production within a 30-minute cycle, completely eliminating postprocessing steps. “The cell’s closed-loop process control, supported by our in-house Quick Identification of Defects system, ensures consistent quality while our automated forming techniques, derived from automotive sector insights, have optimized how we manipulate advanced materials,” Lloyd says.
He adds, “When you combine these capabilities with our focus on sustainability through optimized material nesting and energy-efficient induction heating, we’re not just improving existing processes — we’re establishing new benchmarks for high-rate composites manufacturing that will be crucial for both urban air mobility [UAM] and next-generation single-aisle aircraft markets.”
Airborne
Airborne’s contribution to GKN Aerospace’s automated RTM system centered around its automated ply placement (APP) technology, a system designed to maximize composite component design freedom while ensuring high-rate production capability.

Vision-based automated ply placement (APP) processes multiple composite formats with adaptive algorithms eliminating manual programming. Source | Airborne
“The key innovation in our APP system lies in its ability to fundamentally transform how we approach automated composites manufacturing,” explains Joe Summers, managing director of Airborne UK. “Unlike traditional AFP or ATL systems that are limited to tape formats, our technology can handle virtually any material format — from dry fiber and thermoplastic UD tapes to textiles, films and even metal-layered sheet materials for sandwich panels. The system’s intelligence is built around a vision-based closed-loop control architecture that scans each ply when attached to the end effector, comparing its actual position against expected coordinates to enable real-time trajectory adjustments. This adaptive positioning is crucial for achieving aerospace-grade accuracy.
“What truly sets APP apart is our automated programming approach,” continues Summers. “Traditional robotics require extensive manual programming for each new part or material, but our algorithms can handle thousands of different ply shapes without human intervention. The software considers material flexibility characteristics to optimize gripper force distribution and pickup strategies, preventing issues like sagging between suction points. It even accounts for material-specific challenges — for instance, when handling tacky prepreg, our sensors can detect uncut fibers and automatically pause operations for operator intervention.”
The system’s intelligence extends to quality control and process optimization. Every ply is inspected before placement, and Airborne’s software is constantly learning from this data. Summers notes that the team is developing capabilities where the system can recognize patterns — such as consistently accurate picks from the cutter — and dynamically adjust inspection frequencies to optimize output. “The buffer system adds another layer of sophistication,” says Summers, “enabling out-of-sequence nesting that significantly reduces material waste while maintaining production flow. Looking ahead, we’re implementing ‘Optimize for X’ scenarios where manufacturers can prioritize different parameters — whether that’s maximum output, minimum waste or lowest CO2 footprint — and the system will autonomously adjust its processing strategies in real time. This level of intelligent automation is essential for making advanced composites manufacturing truly scalable for high-rate production environments.”
Assyst Bullmer
Advanced cutting system employs autonomous geometry analysis with integrated fault-mapping for optimized material use. Source | Assyst Bullmer
Airborne’s APP technology integrates Assyst Bullmer’s cutting table technology that enables automated deposition, profiling, preforming, trimming and inspection of dry fiber composite parts for high-rate RTM processing. Assyst Bullmer’s cutting solutions were enhanced through proprietary software development for the aerospace application, creating a direct communication link between CNC cutters and robotic end effectors.
Assyst Bullmer’s director, Martin Sofranko, explains: “We’ve developed algorithms that automatically analyze geometry data, optimize suction cup positioning and manage material handling without operator intervention. The software system incorporates fault-mapping capabilities through digital mapping of material defects, which are then seamlessly integrated into our nesting algorithms for automated defect avoidance. We’ve also engineered specialized DXF filtering mechanisms that can reduce complex geometrical data from thousands of lines to just 12 essential commands, significantly enhancing processing efficiency. The cutting technology itself employs application-specific tools — from drag knives for film-sandwiched materials to driven 10-sided ‘pizza wheel’ blades for dry materials — with intelligent overshoot management for clean fiber release in woven materials.”
The system’s comprehensive integration has yielded a 60-80% improvement in energy efficiency compared to manual operations, Sofranko cites, while enabling mixed-order production dynamics that were previously unattainable in composites manufacturing.
Digital tool development within ASCEND
Digital system development within the ASCEND program has fundamentally reshaped how composite components are designed, manufactured and validated.
Rafinex

Stochastic finite element algorithms incorporate anisotropic properties into multi-terabyte topology optimization for composite structures. Source | Rafinex
Rafinex emerged as a key innovator in this space, developing finite element physics-based topology optimization algorithms that analyze structures beyond idealized digital models.
“Our breakthrough lies in moving beyond traditional isotropic assumptions through stochastic finite element methods that incorporate anisotropic and multi-material optimization techniques,” André Wilmes, CEO of Rafinex, highlights. “This approach has revolutionized how we handle real-world variability in composite structures, enabling us to process unprecedented volumes of data — up to two terabytes in direct solver optimizations. By integrating material constraints and operational conditions into our physics-based topology algorithms, we’re fundamentally transforming the design optimization landscape across aerospace, automotive and broader industrial applications.”
Des Composites
Des Composites contributed vital simulation expertise, particularly in the characterization of fibers during preforming processes at elevated temperatures. The company’s development of automated material card generation systems reduced reliance on analyst expertise, creating more controlled and expedited processes for data handling. Des Composites also developed an in-house facility with dedicated equipment to measure crucial friction properties, as these significantly influence fiber movement and interlayer dynamics under varying pressures.
“By minimizing reliance on individual analyst judgment [through our automated material card generation system], we’ve created a more consistent and accelerated process for translating physical behaviors into our digital twin simulations following the product development from start to finish using composite design for manufacturing, assembly testing and process and performance simulations,” Lorenzo Gagliardi, project manager at Des Composites, says. “This has dramatically reduced the traditional trial-and-error phase in composites manufacturing while maintaining high accuracy in our predictions.”

Automated material characterization system quantifies friction properties during elevated-temperature preforming for high-fidelity simulation. Source | Des Composites
The connection between digital design and physical manufacturing has been significantly strengthened through the combination of Rafinex simulation tools and Des Composites’ systems which, when combined, accurately predict manufacturing outcomes, allowing for the optimization of process parameters before production begins. The correlation between simulated results and actual outcomes has been validated through the production of aerospace components, including the complex geometries of winglet structures.
Loop Technology

AI-powered FibreEYE correlates 3D laser profiling with segmentation algorithms for real-time ply verification. Source | Loop Technology
Development of Loop Technology’s FibreEYE solution marked another significant advancement in digital manufacturing integration. This comprehensive inspection system operates in two crucial domains: in situ material defect detection during manufacturing, and precise placement verification during the layup process. Through extensive research in optimal lighting and sensor configurations, Loop Technology created an AI-powered system capable of generating digital passports for material rolls, documenting defect locations and characteristics. The company’s 3D laser profiler technology, combined with segmentation algorithms, enables real-time monitoring of ply placement accuracy, particularly crucial for complex 3D geometries.
“Our technology combines advanced imaging techniques with AI to create a comprehensive inspection ecosystem,” Alun Reece, managing director of Loop Technology, explains. “By correlating data from our 3D laser profiler with precise positioner information, we’ve developed a segmentation algorithm that can distinguish between material layers and reconstruct complex 3D layouts with minimal gaps.”
National Composites Centre (NCC)
The NCC spearheaded the development of a standardized framework for environmental assessment in composites manufacturing. Its Sustainability Maturity Level (SML) framework transcends existing standards, providing a common language for evaluating environmental impact assessments across the supply chain.
SML addresses six key aspects aligned with the Greenhouse Gas Protocol, including completeness, relevance and transparency, enabling manufacturers to quantify and improve their environmental performance systematically. “Our framework moves beyond simplified global warming potential metrics to address the complexities of composites manufacturing data sensitivity,” James Graham, NCC chief engineer for services, explains. “We’ve implemented a comprehensive scoring system that evaluates sustainability across multiple parameters while protecting proprietary processes. Through our work with GKN Aerospace, we’ve demonstrated how empirical assumptions can be integrated into life cycle assessments when direct supply chain data is unavailable. A starburst-style diagram we developed provides decision-makers with a multidimensional view of sustainability performance, rather than reducing environmental impact to a single metric. This approach has proven particularly valuable in contexts where thermal process data and energy consumption metrics require careful handling due to their commercially sensitive nature.”
This Starburst Diagram is a representation of the maturity of a product’s sustainability data enabling companies to understand the fidelity of sustainability data without the need for sharing sensitive commercial data. Source | NCC
The integration of these digital technologies created a comprehensive ecosystem for data-driven manufacturing. This digital transformation extends beyond individual technologies to create a connected manufacturing environment where data flows seamlessly between design, production and quality control systems, representing an important shift toward Industry 4.0 principles.
ASCEND project outcomes in demonstrator projects
The ASCEND program’s achievements crystallized in two flagship demonstrators: GKN Aerospace’s bladed wingtip and McLaren Automotive’s rear floor component. These demonstrators served as platforms for integrating multiple technological innovations developed within the consortium, showcasing the program’s success in merging aerospace precision with automotive production rates.
The bladed wingtip demonstrator represented the first direct collaboration between GKN Aerospace and McLaren Automotive. GKN designed the component — comprising skins, spars and ribs — based on single-aisle aircraft requirements, while incorporating McLaren’s manufacturing principles. The goal was ambitious: reduce takt time from 1 hour to 30 minutes while maintaining aerospace quality standards. This was achieved through McLaren’s specialized RTM process, originally developed for its Artura plug-in hybrid vehicle’s Carbon Lightweight Architecture (MCLA).
The other demonstrator, McLaren’s rear floor component, showcased the company’s technical development particularly in waste reduction. The component manufacturing process features a novel tape deposition process developed as an alternative to traditional AFP. This high-rate process for composite tape laying achieved near-net shape production with minimal waste, while maintaining the structural requirements of a stressed skin component that provides critical stability during cornering loads and braking forces.
“Our transition to tape-based methods has enabled enhanced fiber architecture with optimal fidelity in orientation and topology” McLaren’s Joseph Elford notes. “By creating net shape preform blanks, we’ve effectively addressed the nesting waste common in directional continuous fiber applications while achieving a 5-10% improvement in stiffness through more precise fiber alignment. This approach, combined with our bespoke resin chemistries optimized for high-rate production, has allowed us to bridge the gap between complex, traditionally low-volume designs and scalable manufacturing methods. The key has been developing a process that maintains absolute uniformity and repeatability, eliminating the need for extensive in-process sensing and multiple feedback loops — essentially achieving a ‘right first time’ methodology that’s transforming how we approach composite structures."
McLaren’s tooling system, developed through ASCEND, requires no cleaning or maintenance between parts, enabling continuous production with robotic part removal and immediate tool reloading — a capability said to be previously unattainable in composites manufacturing. Both demonstrators benefited from advanced tooling innovations, including self-heated shape memory polymer tools that significantly reduced processing time and cost.
ASCEND’s legacy and future impact
As ASCEND concludes, its impact extends far beyond the immediate technological achievements, establishing a new paradigm for cross-sector collaboration. For example, according to Axillium’s Will Searle, the program has successfully created more than 2,000 skilled jobs in the U.K., building a workforce capable of supporting the next generation of composites manufacturing technologies.
Of additional note is the lasting contribution from the NCC’s developed SML framework, representing the industry’s environmental future. This standardized approach to measuring and communicating sustainability across the supply chain provides manufacturers with clear pathways toward net-zero goals. The framework’s integration into GKN Aerospace’s operations has already demonstrated a potential of 80% reduction in energy consumption through the transition to out-of-autoclave processes, setting new benchmarks for sustainable manufacturing.
Carr also emphasizes how ASCEND has transformed GKN’s approach to future aircraft component manufacturing: “The program’s success in achieving production rates of 100 shipsets per month positions GKN Aerospace to meet increasing demands from both traditional aerospace and emerging UAM markets. The integration of automotive-inspired automated manufacturing processes has created a template for future production facilities, with the potential to significantly reduce both costs and environmental impact.”
Looking ahead, Axillium’s structured innovation framework, developed and refined through ASCEND, provides a blueprint for future cross-sector collaborations. The program’s success in managing complex partnerships among 15 diverse organizations demonstrates how traditional industry boundaries can be transcended to achieve common goals. This model of collaboration, supported by digital integration and standardized sustainability metrics, sets a new standard for industry cooperation.
The program’s legacy is perhaps most evident in its influence on future product development strategies. Both aerospace and automotive partners now approach design and manufacturing with a broader perspective, incorporating lessons learned from each other’s domains. This cross-pollination of ideas, combined with the establishment of a robust supply chain and skilled workforce, will continue to position the U.K. composites industry for sustained growth and innovation in the decades ahead.