Prodrive Scores £10 Million in Contracts for Carbon Parts

The big manufacturers of luxury and performance cars have chosen Prodrive’s specialist manufacturing division to supply carbon composite parts for 5000 vehicles over the next six years, according to the company. The deals, worth a combined total of more than £10m, will include parts as small as door mirrors and as large as the whole rear diffuser.

Prodrive says that the two luxury carmakers involved are using carbon components for the exterior of their cars for the first time, having only used carbon for decorative interior trim previously. These parts will include bumper inserts and sill extensions, which will remain unpainted, presenting the composite’s weave as the finished, visual surface. For the sports car manufacturer, Prodrive will build a full carbon interior trim, as well as major external sub-assemblies.

“These are the largest ever contracts for our composites division, both in terms of volume and value, and mark a significant step by vehicle manufacturers towards the increased use of carbon fibre for exterior applications,” says Prodrive’s composites manager Ian Handscombe.  “These and other major contracts for motorsport and aerospace businesses will see us double our turnover in 2011.”

The exterior composites must combine the necessary robustness with an exceptional surface finish, including the consistency and direction of weave in the fabric. “There’s no hiding anything under a layer of paint. Our track record with both lacquered and unlacquered finishes has given customers the confidence that we can deliver the standards required.”

With many of the cars destined for hot countries, a strong emphasis is placed on exhaustive environmental testing to ensure durability in extreme conditions.

The orders mean a significant increase in manufacturing volume for Prodrive. As a result , the company has developed its production processes to facilitate simultaneous working by multiple skilled operators.