GKN Aerospace and Partners Successfully Complete ASCEND Programme, Transforming High-Rate Composite Manufacturing
A Landmark Achievement in Composite Manufacturing
GKN Aerospace, in collaboration with McLaren Automotive and other UK partners, has successfully completed the ASCEND (Aerospace and Automotive Supply Chain Enabled Development) programme. This four-year, £39.6 million initiative has revolutionized the UK’s high-rate composite manufacturing capabilities, emphasizing automation, Industry 4.0, and sustainability.
A Collaborative Effort for Future Mobility
The ASCEND programme was funded through a £20 million commitment from industry and £19.6 million from the UK Government via the Aerospace Technology Institute (ATI). It aimed to accelerate the adoption of composite technologies, industrialize new materials and processes, and prepare for high-volume production needs across the aerospace and automotive industries.
Bringing together 16 partners from across the UK’s composites supply chain, the project combined expertise in automation, material processing, and tooling. Led by GKN Aerospace, key contributors included 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 strategic support from Axillium Research.
Key Innovations and Technological Advancements
Advancing Automation and Material Processing
The ASCEND programme facilitated groundbreaking advancements in composite technology. Notable achievements include:
- Composite Topology Optimization: Rafinex contributed cutting-edge methods to enhance structural efficiency.
- Fast-Cure Prepreg Technology: Developed by HEXCEL and Syensqo, enabling quicker production cycles.
- Advanced Bonding Techniques: FAR and HIVE pioneered cross-sector joining mechanisms to improve assembly efficiency.
- Automated Manufacturing Systems: Loop Technology and Airborne developed high-precision automated ply placement technologies, enhancing production speed and repeatability.
- Resin Transfer Molding (RTM): GKN Aerospace’s RTM cell showcased advanced liquid composite molding for aerospace applications.
Sustainability and Environmental Responsibility
Sustainability was a core pillar of ASCEND. The NCC introduced a Sustainability Maturity Level framework, allowing manufacturers to assess and mitigate the environmental impact of composite production. This initiative aligns with broader industry goals to reduce carbon footprints and promote eco-friendly materials and processes.
Demonstrator Projects: A Proof of Concept
The programme’s success was exemplified by two flagship demonstrator projects:
- GKN Aerospace’s Bladed Wingtip: Showcasing aerospace-grade precision in composite manufacturing.
- McLaren’s Rear Floor Component: Demonstrating how aerospace composite techniques can be adapted for high-rate automotive production.
These projects validated ASCEND’s technological breakthroughs, proving the feasibility of high-volume, cost-effective composite manufacturing.
Impact on Jobs and the UK Supply Chain
ASCEND was managed from GKN Aerospace’s £32 million Global Technology Centre in Bristol, supporting up to 130 jobs throughout 2023 and 2024. By fostering a skilled workforce and strengthening the UK’s composite supply chain, the programme has laid the groundwork for sustained innovation and competitiveness in global markets.
Industry Leadership and Future Prospects
John Pritchard, President of Civil Airframe at GKN Aerospace, emphasized the programme’s significance:
« GKN Aerospace has deep knowledge and expertise in composite technology, and we are proud to have led this consortium. 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.
Successfully developing and demonstrating high-rate manufacturing capabilities across the UK supply chain has reinforced our position as an industry leader and underscored our commitment to sustainability. With the support of the Aerospace Technology Institute, which continues to play a vital role in advancing the UK’s position in next-generation aircraft, we have delivered key technological breakthroughs while achieving benchmark levels of price, quality, and repeatability. »
A Lasting Legacy for Composite Manufacturing
The ASCEND programme has not only achieved its technological goals but has also set a new standard for cross-sector collaboration. By fostering a robust supply chain and a skilled workforce, the initiative has positioned the UK composite industry for sustained growth and leadership in advanced manufacturing.
As industries continue to move towards more energy-efficient and sustainable solutions, the groundwork laid by ASCEND will serve as a critical foundation for the future of high-rate composite manufacturing in aerospace, automotive, and beyond.
