DESIGN - ENGINEER - master - mould - manufacture
The two directors now have a combined total of sixty years of experience working on automotive and motorsports composite projects in the above five disciplines.
This journey began following the completion of automotive engineering degrees at the University of Hertfordshire in 1988. At this time everything was done by hand and some very steep learning curves were climbed. In a few short years one hundred and forty vehicles with a glassfibre reinforced polyester monocoque had been produced. (1994)
Attentions turned to carbonfibre/epoxy composites and the possibilities offered by their superior mechanical properties. An autoclave large enough for car sized parts was ruled out on cost. Vacuum Infusion became the focus of attention as a realistic alternative and a carbonfibre/epoxy monocoque was designed and manufactured using this process.
This was combined with a set of Mitsubishi Evo 6 runnng gear. (2004)
The knowledge accrued during this project was used to start producing parts for Prodrive GpN Subaru rallycars, and then subsequently WRC (Mini), GTE (Aston Martin), GT3 (Nissan GTR), CRC (Golf) and now WRX (Megane). (2008-2018)
Today XWorks employs seven people, in addition to the two directors, operating in five hundred square metres of space. Five ovens capable of accommodating car sized panels are available for curing purposes along with a paint booth, three axis CNC milling machine and a seven axis three metre reach robot.
The facilities are a step on from thirty years ago as are inevitably the computing resources. Projects are almost exclusively CAD based now and we have well in excess of ten thousand hours of CAD experience specifically working with composites in the automotive and motorsports fields.
Over the past thirty years a huge amount of knowledge has been acquired in the design of composite parts for use in these applications. Prioritising parameters of component design with an appreciation of the costs involved to achieve the 'solution'....