Carbon ThreeSixty Develops TFP-Based Composite Aerodynamic Wheel Cover for Lightweight Automotive Applications
BY Composights
Published: 02 May 2026
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Carbon ThreeSixty, a UK-based composite design and manufacturing company, has developed an aerodynamic wheel cover using Tailored Fibre Placement (TFP) technology to improve vehicle efficiency through lightweighting and reduced aerodynamic drag.
TFP is an automated process that enables precise placement of fibres in specific orientations within the structure. This allows optimisation of material distribution at the fibre level, improving mechanical performance without adding unnecessary mass. Compared to conventional prepreg-based designs, the structure reduces material usage while maintaining structural integrity.
The TFP-optimised design reduced the number of plies required in the structure by three compared to the baseline prepreg configuration. Despite this reduction, the component achieved a 22 3 percent increase in stiffness. The automated fibre placement process also improves manufacturing repeatability and reduces labour requirements associated with manual layup.
The development addresses limitations of traditional prepreg systems, which often require multiple layers to meet stiffness and strength targets, leading to increased weight, longer production times, and higher costs. TFP enables localised reinforcement without increasing overall laminate thickness, supporting more efficient structural designs.
Aerodynamic wheel covers are used to reduce airflow disruption around rotating wheels, which can account for a significant portion of total vehicle drag at higher speeds. By improving airflow and reducing turbulence, such components contribute to increased vehicle efficiency and extended range, particularly in electric vehicles.
For the composites industry, the project demonstrates the potential of automated fibre placement technologies such as TFP to optimise performance-critical automotive components. The ability to reduce material usage while improving stiffness and manufacturability supports broader adoption of advanced composite processes in high-volume applications.
Source: Carbon
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