Creator of bespoke Land Rover vehicles increases capacity and expands into North America thanks to reliable and high-quality carbon fibre component supply from Prodrive Composites
Milton Keynes, UK, Nov 16 2018… Prodrive Composites is enabling Overfinch, the creator of bespoke Land Rover vehicles, to significantly increase production capacity by supplying consistent, high-quality carbon fibre components. Prodrive is fully integrated into Overfinch’s supply chain, providing finished, ready-to-fit components matching the company’s demanding build schedule
As well as manufacturing the components, Prodrive Composites worked with Overfinch to design the new conversion packages for the Range Rover and Range Rover Sport models. Using state-of-the-art scanning techniques, accurate dimensions of the vehicle were used to produce CAD models of the conversion packages. Once the design was finalised, Prodrive prepared the tooling and produced prototype parts to ensure fitment and aesthetics were as expected.
“Prodrive’s expertise in composite manufacture was critical to optimising the design, ensuring that high-quality, A-surface components could be produced consistently,” explained Kevin Sloane, Chairman, Overfinch. “Our partnership with Prodrive has enabled us to significantly increase production and move into new markets. Prodrive collaborates with us on an ongoing basis including design work, product revisions and production. It can deliver fixed volumes each week to match our build order and provide components that are significantly easier to install than those we were using in the past.”
Prodrive utilised a new additive manufacturing technology to produce a backing that accurately secures the mounting bracketry and clips to the carbon components, ensuring it fits directly to the vehicle’s OE fixings. This process has significantly improved ease of fitment and directly reduced the build time per vehicle.
“Often companies like Overfinch request composite parts from suppliers, only to receive pieces that require modification and adjustment to make them fit,” explains Richard Gregory, Quality and Engineering Director, Prodrive Composites. “Not only are we able to design and deliver components that fit straight on using the OE fixtures, we are also able to deliver the parts as and when they need them.”
Prodrive is producing both ‘visual’ and painted carbon composite conversion packages. Using its own paint facilities, Prodrive Composites was able to supply Overfinch with completed components, this ensured that regardless of how the car was specified, the composite parts were supplied to match specific vehicles within the build order. The streamlined process has reduced Overfinch’s average build time for a vehicle’s exterior from a week down to a day.
“We sequence delivery and have a dedicated project manager that resolves any queries, concerns or difficulties that arise,” concluded Gregory. “Being able to paint in-house and deliver components to Overfinch’s build schedule is a significant advantage. These factors have led to a strong working relationship between Overfinch and Prodrive Composites and we are excited to continue building this relationship.”
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About Prodrive Composites
Prodrive Composites designs and manufactures advanced lightweight structural and non-structural composites for a wide range of applications across the automotive, motorsport, aerospace, marine, defence and other specialist sectors. It is the largest UK manufacturing operation using state of the art processing to deliver high quality parts made from autoclave cured pre-impregnated materials. This process is the highest performing, most reliable and best established within the composites industry today. Its clients include nearly every leading UK vehicle manufacturer: Aston Martin, Lotus, Bentley, Jaguar Land Rover, McLaren and Rolls Royce.
Prodrive is one of the world’s largest and most successful motorsport and technology businesses. Over 500 staff are employed across its Banbury headquarters and composites manufacturing facility in Milton Keynes. While the company is perhaps best known for motorsport, today it is just one part of an organisation that in the last decade has diversified to become a technology business working in a range of sectors and providing a range of services. Within the Prodrive Group, there are four distinct but interconnected business areas: Motorsport, operating race and rally programmes for vehicle manufacturers and global brands; Advanced Technology, providing innovative technology for the automotive, aerospace, defence and marine sectors; Composites, developing lightweight composite components for the automotive, aerospace and marine sectors; and Bespoke Collections, a clothing and accessories manufacturer for leading brands.