Red Bull Advanced Technologies has joined forces with Singer to design a strategy for increasing the torsional stiffness of Type 964 Cabriolets and Targas reimagined through Singer’s Classic Turbo services.

Singer’s process begins when a 964-generation Porsche 911 Cabriolet or Targa is provided for personalised restoration. The vehicle will be fully disassembled to expose the steel monocoque, which will then be assessed, cleaned and prepared for the subsequent stages of restoration.

Through the collaboration, Red Bull Advanced Technologies has provided its expertise in simulation and structural analysis. The Porsche 964 chassis has been digitally modeled using scanned data and manual measurements, with finite element analysis (FEA) software used to calculate the torsional stiffness of the different variants of the car (with and without a roof). The FEA model was then refined until the predicted stiffness values matched those recorded in physical tests.

Having correlated the model, Red Bull Advanced Technologies used it to assess which parts of the open-roof structure were working the hardest to resist the applied torsion, primarily through looking at the strain energy. Using this, a formation of 13 carbon fiber structures were then designed to reinforce these parts, while still respecting the need to preserve the original Type 964 chassis and accommodate packaging requirements. The reinforcing structures were then built into the correlated FEA model, and tuned to give the required torsional stiffness level.  A prototype vehicle featuring the reinforcing structures was then tested as a final validation of the analysis work.

The 13 carbon fiber reinforcing structures developed by Red Bull Advanced Technologies are bonded to the 964 monocoque during the restoration process, increasing torsional rigidity by 175%. This increased chassis rigidity benefits handling, braking and overall refinement, with the driving experience of the open-roofed cars now matching that of the coupe.

Rob Gray, technical director of Red Bull Advanced Technologies, said, “Our expertise is derived from relentless competition and success at the very highest levels of motorsport. We apply that expertise to engineering challenges across a wide variety of projects and industries. The challenge from Singer was to increase the stiffness of the open-roof Type 964, giving it the same dynamic performance as the coupe while minimizing additional weight. The careful balancing of performance against weight is extremely familiar to us and we’re delighted to have been able to support Singer and their clients with this solution.”

Mazen Fawaz, chief strategy officer at Singer, said, “Our clients are some of the most discerning drivers in the world. To achieve the standards they have come to expect, we work only with the best, and our search for expertise in this area led us to Red Bull Advanced Technologies. Since 2009 our approach has brought heritage together with cutting-edge engineering, and Red Bull’s mastery of advanced materials, simulation and structural analysis perfectly exemplifies this approach. The results underline the extraordinary lengths we go to in our relentless pursuit of excellence.”

Related news, Unnamed Mercedes‑Benz Mythos model undergoes arctic testing

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Škoda Motorsport has leveraged Bcomp technologies in its 2025 Enyaq RS Race. The material technology has reportedly contributed to a weight cut of 316kg in a pilot project demonstrating sustainable lightweighting.

The all-electric concept car is inspired by Škoda’s rally DNA. It is based on the Škoda Enyaq Coupé RS production model and features a host of upgrades and innovative technology demonstrations.

Sustainable lightweighting 

For the 2025 Enyaq RS Race, Škoda Motorsport engineers took advantage of Bcomp’s lightweight, sustainable bio-composites to attain a total weight savings of 316kg versus the production Škoda Enyaq Coupé RS. This was achieved using parts made from Bcomp’s ampliTex and PowerRibs.

Bcomp’s technologies were used for the interior and body of the vehicle. Applications included the bumpers, fenders, roof vent, rear wing, dashboard, door panels, footrests for the driver and passenger and a replacement panel for the standard model’s panoramic glass roof. In total, 16 different vehicle components were replaced with sustainable material alternatives.

Ken Kruck, motorsport sales representative at Bcomp, said, “Our long-standing relationship with Škoda has been incredibly successful and has explored the potential of our sustainable lightweighting technologies in motorsport and extremely innovative concept vehicles. Now, with the Enyaq RS Race, we have demonstrated our ability to move this collaboration beyond the rally stage and onto the road with volume production. Lightweight, sustainable materials will play a critical role in the future of the automotive industry, and we are excited to further explore this potential with Škoda.”

An alternative to carbon fiber 

Bcomp’s technologies offer comparable stiffness and weight to carbon fiber while cutting CO2 emissions by approximately 85%. The primary technology used in motorsport and automotive applications is ampliTex, a technical fabric made from renewable flax fibers. These woven fibers help to dampen vibrations and contribute to weight reduction. Composite parts made from ampliTex are often reinforced with PowerRibs, a technology that increases the stiffness of thin-walled shell structures.

Preparing for production 

Škoda Motorsport has put bio-composites to the test in challenging conditions in the Rally2 class. The company is also exploring the potential of these technologies in production automotive applications.

Bcomp’s technologies originated in sports equipment and motorsport applications but the company has conclusively demonstrated its capacity for high-volume automotive production in several major projects for international OEMs.

Jakub Jareš, the project manager for the Enyaq RS Race, said, “At Škoda Motorsport, we are always looking to take advantage of new technologies and materials. The cooperation with Bcomp in the field of composites enabled us to achieve significant weight savings while at the same time demonstrating that motorsport can be sustainable. In combination with a fully electric vehicle, this approach makes perfect sense to us. Looking ahead, this material will continue to play an important role in our future projects, and it holds great potential for use in series production, where it could also find valuable applications.”

In related news, Vittori unveils hybrid hypercar, designed in collaboration with Pininfarina

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Mercedes AMG Petronas F1 Team has debuted a bio-based carbon fiber composite material on its W16 race car at the Azerbaijan Grand Prix last weekend (September 21).

The rear brake duct wheel shields on George Russell’s W16 – which crossed the line P2 in Baku – were developed using a new resin that includes 30% bio-based materials. This is the first time the team has used sustainable carbon fiber composites on a technically performant component in race conditions. This bio-based material advancement was made in close partnership with Syensqo.

Applying these materials to the rear brake duct wheel shields, with their intricate aerodynamic surfaces, demonstrates that the technology can withstand the extreme conditions of Formula 1 racing and that it has the potential for widespread adoption across the sport, the team said. Material innovation is a crucial step for Mercedes-AMG Petronas in reaching net zero across all scopes by 2040.

Head of sustainability Alice Ashpitel commented, “We are proud to be powering sustainable innovation within Formula 1, introducing sustainable carbon fiber composites on a technically performant component. This project with Syensqo highlights our commitment to reducing our environmental impact while maintaining the highest standards of performance.

“By integrating bio-based resin within a carbon fiber composite material, we are setting a new benchmark for the future of motorsport and beyond. The fact that these materials have been derived from by-products associated with the creation of bio-diesel is an added benefit and indicates the power of advanced sustainable fuels.”

Rodrigo Elizondo, president of Syensqo Composite Materials, added, “We are pleased to see our project with Mercedes come to life on the W16 race car. Our bio-based resin technology represents a significant step forward in sustainable materials innovation.

“By replacing traditional petroleum-based components with those derived from renewable sources, we are not only introducing circularity in our product design but also paving the way for future innovations. We are very pleased to see this material applied in such a high-performing environment, showcasing its potential for broader applications.”

Toto Wolff, CEO and co-owner of Mercedes-AMG Petronas F1 Team, said, “In an era where innovation drives performance and shapes industry futures, the pursuit of smarter, faster and more efficient technologies has become a defining challenge of our time. This project not only reflects our commitment to sustainability but also highlights the role of Formula 1 as a testbed for pioneering technologies that can benefit a range of industries. Our sport is the world’s fastest test lab, and these innovations represent our relentless pursuit of performance and appetite to contribute beyond the grid.”

In related news, Citroën signs drivers Jean-Éric Vergne and Nick Cassidy for Formula E debut

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Bcomp has collaborated with Japanese composite specialist Tras to develop racing bodywork for the Suzuki Motor Corporation’s factory race team, Team Suzuki Carbon Neutral (CN) Challenge. The 2025 Team Suzuki CN Challenge GSX-R1000R will have feature fenders, winglets and fairings made from Bcomp’s natural-fiber composites, ampliTex and powerRibs.

Originally, Tras used Bcomp technologies to develop prototype bodywork for the Suzuki ECSTAR MotoGP team, increasing awareness of modern natural-fiber composites. This technical demonstration prompted the latest collaboration to produce race-ready components for Team Suzuki CN Challenge as it enters the experimental class of the 2024 and 2025 FIM Endurance World Championship (EWC) Suzuka 8 Hours.

Bcomp’s ampliTex is a technical fabric designed for composite layups and can be strengthened by powerRibs, a reinforcement structure. Both composites harness the natural characteristics of flax fibers to produce parts with excellent stiffness and damping properties, while also being lightweight. Critically, they offer up to 85% CO₂ emission reduction from cradle to gate, and viable end-of-life solutions compared with carbon fiber.

At the 2025 Suzuka 8 Hours, the team raced with 100% sustainable fuel, racing tires with recycled material, bio-sourced engine oil and an eco-friendly titanium muffler.

Shinichi Sahara, head of Suzuki Motorsports, said, “The 2025 Team Suzuki CN Challenge GSX-R1000R is an incredible machine that sets ambitious goals to simultaneously minimize environmental impact and drive greater performance. Embracing the natural color of ampliTex in our bodywork and winglets has great visual impact – you can see a sustainable material in action. We hope to expand our use of Bcomp and increase awareness of these technologies across the motorsport and motorcycle industries. We look forward to our future work with Tras and Bcomp, working together to achieve new goals in sustainable motorsport.”

Masanao Nitta, representative director at Tras, commented, “These innovative natural-fiber parts were made possible thanks to Bcomp’s material technologies. The new ampliTex prepreg even withstood the hot and humid manufacturing environments typical of Southeast Asia. With this improvement, we were able to further enhance the performance and aesthetic of the ampliTex parts. This year, there are both more parts and larger parts on the Suzuki CN Challenge GSX-R1000R that have been made from ampliTex and powerRibs – a major step forward that opens wider possibilities. We look forward to seeing these parts raced at Suzuka, proving their capability at the highest level.”

Ken Kruck, sales representative motorsport at Bcomp, added, “Competing at Suzuka 8 Hours with natural-fiber composite bodywork is the ultimate proof point. It’s a conclusive demonstration that the performance demands of top-tier motorsport can be met by modern sustainable material technologies – performance and sustainability are no longer mutually exclusive. We look forward to our continued work with Tras and Team Suzuki CN Challenge.”

In related news, Bcomp, Porsche Motorsport and Four Motors have unveiled new Bcomp gray-toned components on the Porsche GT3 Cup car, representing what the companies say is “the next evolution of natural-fiber composites in motorsport”

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Bcomp, Porsche Motorsport and Four Motors have unveiled new Bcomp grey-toned components on the Porsche GT3 Cup car, representing what the companies say is “the next evolution of natural fiber composites in motorsport”.

The Four Motors Porsche GT3 Cup will use exterior body components produced with Bcomp’s grey ampliTex, an updated aesthetic for the natural fiber composite material.

This collaboration builds on previous projects with Porsche Motorsport, including the Porsche 718 Cayman GT4 CS, Porsche 718 GT4 RS Clubsport and Porsche Mission R. This latest project focused on performance-oriented sustainable design, combining visual design and material sustainability in a fully integrated solution.

Ken Kruck, sales representative motorsports at Bcomp, said, “Our collaboration with Porsche Motorsport and Four Motors provides an avenue for joint innovation. These new processes allow us to deliver a new look for natural fiber composites, that is not only high-performing, but also road relevant. Following the success of coloured ampliTex in road car interiors, we are proud to bring this Bcomp grey as our signature motorsport color to race cars, as shown on this stunning Four Motors Porsche GT3 Cup Car.”

The Bcomp grey tone of the parts showcases how natural materials can be tailored to blend with high-performance design, beyond the natural gold-brown appearance of flax-fibers seen in earlier models. Road relevance is further reinforced by a painted surface on the exterior parts, rather than the foil typically used in race components. While adhesive films (foils) are used to enable rapid design changes, the use of paint further demonstrates the feasibility of natural fiber composites in high-performance road cars.

The hood, rear wing end plates and front bumper dive planes of the Four Motors Porsche GT3 Cup car have been reverse-engineered by Bcomp. Previously made from aluminum and carbon fiber for the production race car, the parts were manufactured using Bcomp’s coloured ampliTex flax fiber reinforcement fabrics.

When produced in an autoclave in combination with Bcomp’s powerRibs, natural fiber parts can achieve an equivalent stiffness and weight to carbon-fiber components, said Bcomp. They also meet the same high safety and quality standards, offering 250% improved vibration damping and improved crash behavior, mitigating against the splintering often associated with carbon fiber, according to Bcomp. AmpliTex is manufactured with less energy, enabling a CO₂ emission reduction of up to 85%.

“A major paradigm shift is taking place. In showcasing the latest advancements in sustainable technologies through racing, we are not only inspiring change within motorsport but also facilitating progress in other vital mobility sectors, further demonstrating our commitment to – and ambition for – a greener future for the sector,” commented Thomas von Löwis of Menar, CEO and driver at Four Motors.

Matthias Scholz, director GT Racecars at Porsche Motorsport, added, “The implemented components of the Four Motors Porsche GT3 Cup car were created in collaboration with Bcomp and Porsche Motorsport to demonstrate the next step in the material development of natural fiber components. These findings will be incorporated into future products.”

In related news, MoTeC has launched an ergonomically designed, lightweight racing wheel, engineered with a full carbon-fiber body and an integrated C125 display. Each component has been selected with input from professional FIA series drivers

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MoTeC has launched an ergonomically designed, lightweight racing wheel, engineered with a full carbon-fiber body and an integrated C125 display. Each component has been selected with input from professional FIA series drivers.

Alireza Tashakori, manager of e-mobility business development and application at MoTeC, commented, “We’ve had this idea for a long time. When the opportunity came up with a pilot client, we decided that if we wanted to do this, we would do it as a product off the shelf. So, we seized the opportunity and then worked with some collaborators to make it happen.”

The racing steering wheel is fully FIA marshaling controlled, meaning it is integrated with the FIA’s marshaling system, which allows automated, real-time communication between race control and the driver through the steering wheel’s display or lights.

Tashakori added, “We can split the CAN into private CAM and public CAN. And we offer all the standard logging features that motorsports teams typically require, including secure logging capabilities. This is handled through our KeePass function, which is an encrypted, cloud-based data storage system.”

He continued, “We added the capability to display text to the driver via an external controller, so you can send the CAN command and then you message the driver, in addition to marshaling messages.”

The racing steering wheel is due to be FIA crash tested by the end of the year.

In related news, Cosworth unveiled its next-generation CCW Mk3 steering wheel at the opening round of the IndyCar championship in St Petersburg, Florida, on March 2

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Goodyear has announced that starting with the 2025 season of the Goodyear FIA European Truck Racing Championship (ETRC), its truck racing tires will be produced using 55% sustainable materials.

The sustainable content is achieved through the use of carefully selected ingredients, such as silica produced from waste rice husk ash and carbon black sourced from alternative feedstocks.

Innovation in truck motorsport

Goodyear has been a key player in the European Truck Racing Championship series since 2003, with the racing championship serving as a platform for testing next-generation tire solutions, with insights gained from the racetrack influencing the development of Goodyear’s commercial truck tires.

In the Goodyear FIA ETRC, regulations require a single tire to perform consistently across a wide range of circuits and weather conditions, including dry, wet, cold and hot surfaces. Goodyear’s latest truck racing tire, which was introduced last season, features an advanced compound designed to enhance grip, particularly in wet conditions. and also features improved durability, reducing the total number of tires used throughout the championship – which helps teams maintain optimal performance while improving overall efficiency in tire use.

“With the introduction of Goodyear’s next-generation 55% sustainable material racing tire, we take another step toward sustainability transformation of our truck racing series,” said Georg Fuchs, managing director of ETRA. “This partnership demonstrates that sustainability and performance can go hand in hand, paving the way for a more responsible future in both racing and road transport.”

“The Goodyear FIA ETRC serves as an additional proving ground for the latest advancements in truck tire technology,” said Maciej Szymański, marketing director, commercial EMEA, Goodyear. “By increasing the share of sustainable materials in our racing tires, we not only support the championship’s sustainability agenda but also pave the way for broader innovations that benefit the entire transport industry.”

Goodyear has also earned the FIA’s three-star environmental accreditation for its sustainability work in the FIA ETRC as well as across its wider motorsport programs, including the FIA World Endurance Championship, Le Mans 24 Hours and European Le Mans Series.

In related news, Tyrecycle has partnered with Motorsport Australia and the Shell V-Power Motorsport Park at The Bend to carry out a tire recycling pilot program on May 23-25.  The pilot project saw 168 tires recycled over the course of the three-day event in South Australia. Read the full story here

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Lyten, the supermaterial applications company and 3D graphene specialist, has launched the new venture Lyten Motorsports,  in partnership with Indycar Experience, to bring Lyten’s material science innovations to motorsports parts through.

Lyten’s 3D graphene is a foundational, carbon-based material that can be tuned to meet the specific needs of high-performance applications, impacting material properties like strength, weight, conductivity and permeability.

The company is currently using the 3D graphene platform to build lithium-sulfur batteries approaching twice the energy density of lithium-ion while eliminating 85% of the mined minerals, such as nickel, cobalt and graphite. Lyten is using the strength, weight and conductivity of its materials to design and build parts that “push the limit of strength-to-weight ratio in motorsports”, it said.

“Material science is creating a future that is lighter, stronger and safer, while reducing our impact on the planet,” said Dan Cook, Lyten co-founder and CEO. “Motorsports sit at the apex of materials innovation, where small improvements make the difference in speed and safety. The introduction of carbon fiber revolutionized the sport, and we believe Lyten 3D graphene can be the next materials revolution in motorsports.”

Lyten will continue to execute materials research and development at its headquarters in Silicon Valley and has opened a design and manufacturing facility in Indianapolis in Indiana, for motorsport parts, co-located with the Indycar Experience headquarters.

The company is currently manufacturing 3D printed parts using its proprietary filaments and adhesives and quickly expanding into autoclave manufacturing to meet market demands. Lyten has said it will be further enhancing the performance of carbon-fiber parts and identifying metal parts that can be converted into lighter, lower cost composite parts. Lyten Motorsports says it plans to develop parts for a broad range of US and international racing series.

“Motorsports is a high-growth, technology-enabled industry and challenge number one is pushing the bounds of known materials. There is tremendous demand for that next materials innovation and Lyten has it with its 3D graphene platform,” said Scott Jasek, CEO of Indycar Experience. “I am excited to use our base in Indianapolis to scale up US manufacturing of motorsport parts and bring with it technology focused jobs.”

The company has been testing new material designs on the Indycar Experience two-seat Indycar for more than two years and will continue to use the platform to accelerate parts development.

In related news, Porsche Engineering recently developed the TABASKO construction method, in which polypropylene components are reinforced with strategically placed carbon fiber tapes. Click here to read the full story

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Dymag, Borbet and Advanced International Multitech (AIM) have announced a strategic partnership to accelerate the development and industrialization of carbon hybrid and composite wheel technology for the automotive and motorcycle industries.

This collaboration brings together Dymag’s expertise in carbon wheel technology, Borbet’s position as premium aluminum wheel producers for OEM and aftermarket, and AIM’s advanced manufacturing capabilities to establish a new standard in lightweight, high-strength wheel solutions.

The collaboration leverages Borbet and AIM’s established supply networks, AIM’s scalable production infrastructure and Dymag’s technical expertise and patented BX-F designs to create a “robust, high-quality supply solution for global markets”, the companies stated.

Through close technical alignment and coordinated development efforts, carbon hybrid wheels will be seamlessly integrated into OEM production lines, delivering a validated, lightweight solution for future vehicles, they added.

The collaboration is a critical step toward widespread adoption, ensuring enhanced durability, efficiency and performance for modern automotive and motorcycle applications.

Christopher Shelley, executive chair at Dymag, said, “This partnership enables Dymag to bring our carbon wheel technology to the rapidly expanding OEM market, supporting the industry’s shift toward lightweight, high-performance solutions.”

Burkhard Plett, CEO at Borbet, said, “By combining Borbet’s OEM expertise with Dymag’s pioneering carbon wheel technology, we are creating a scalable solution that will redefine high-performance wheels for auto makers worldwide.”

Mike Chou, general manager, AIM Group, commented, “Our manufacturing expertise in advanced composites, combined with Dymag’s patented wheel technology, positions us to bring industry-leading lightweight solutions to market at scale.”

In related news, Yamaha and Lola Cars have agreed to continue their technical partnership agreement beyond 2027 to develop and supply high-performance electric powertrains for Formula E. Click here to read the full story

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Porsche Engineering has developed the TABASKO construction method, in which polypropylene components are reinforced with strategically placed carbon fiber tapes. This helps reduce the use of plastic materials and increase the use of post-consumer recycled material, and supports lightweighting without sacrificing rigidity. TABASKO takes its name from the German for ‘tape-based carbon-fiber lightweight construction’.

Plastic polypropylene (PP) is often used in the interior of a vehicle. But PP has its disadvantages. Michael Johann, specialist project manager for body system development, explained, “Rigidity and heat resistance do not count among the positive properties of polypropylene. Glass fiber is typically added to improve it.” This glass-fiber-reinforced plastic is called PP-GFx.

Johann is “constantly evaluating new design principles that can be used to combine maximum strength and minimum weight”, Porsche says.

This led to the creation of the TABASKO process, based on the hypothesis that PP currently used could be reinforced with a few continuous carbon fiber tapes, reducing wall thicknesses of components without losing stability.

Prototype

In a collaborative effort, Johann and Porsche materials expert Frank Häusler received support from Hubert Stadtfeld, project manager for lightweight construction in production development for strategic product and process design at Porsche Engineering, to test the TABASKO prototype on the luggage tray of the Porsche Taycan.

Originally made of glass-fiber-reinforced plastic, the series component was 65cm long, 120cm wide and 52cm high. For the TABASKO test, a 1.8mm-thick PP-GFx, reinforced with 0.2mm thin carbon-fiber tape, was used. The percentage of carbon by weight was 1%.

Three tests were carried out with the prototypes: a comparative punch test on both the series-production luggage tray and its counterpart made of TABASKO material; a four-point bending test; and an impact strength test.

Test results

For the punch test, a 66% higher compressive force on the TABASKO luggage tray was required to achieve the same maximum permissible deflection. At the same time, the component was 15% lighter than the series-production luggage tray.

For the four-point bending test, developers cut rectangular strips out of the bottom surface of the luggage tray. The strips were then bent from both sides, each at room temperature and 90°C. The tapes were placed in the component as upper and lower belts in alternation, forming a “virtual sandwich”. The spacing in the peripheral positions enabled high flexural rigidity with minimal use of tape. “Clearly visible was that the rigidity of the tape-reinforced samples was higher by a factor of 2.5 to 2.8,” explained Häusler.

The third impact strength test was a test appropriate for when foam injection molding is used, as it is in the manufacture of the TABASKO material. “In doing so, this results in foam structures that could cause the impact resistance of the base material to suffer,” said Johann. The test showed that, in combination with tape on the tensile side, the impact resistance was approximately five times better.

Production

“Now came the most important step: transfer to series production,” said Häusler. “The question was, how can you produce up to 80,000 parts a year— in a fully automated way and cost-neutral compared to today’s process?”

Johann, Häusler and Stadtfeld worked together with a supplier to develop a production process using conventional automated injection molding machines. “The tapes are inserted into the forming tools by means of a handling device and attached to either the top or the bottom of the component using vacuum channels,” explained Johann. “In principle, new machines or processes are not required, which is extremely advantageous for production costs.”

The preliminary development of the new material has been completed and the technical department responsible for the luggage trays has already signaled interest in series production for future vehicles. Discussions are currently ongoing with the plastic suppliers.

Six patents have been filed for TABASKO, for the material structure, the production method, the tool technology and the process sequence in series production.

In related news, a research team at Wichita State University has developed a new nanocomposite material that could significantly enhance the strength, durability, multifunctionality and performance of composite structures. Click here to read the full story

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