Breakthrough Aerospace Material - BAM

A 3D weaving machine will soon produce aircraft wing spars and car body panels from a single piece of carbon fibre, stitching the fibres together rather than layering them. Today’s composite parts are built by stacking sheets of pre-impregnated carbon fibre and curing them in an autoclave. This is slow, expensive, and creates weak points where layers can separate. The BAM project replaces that process with three-dimensional weaving, where fibres are interlaced in all directions. This eliminates the need for autoclaves, reduces assembly time, and produces structures that resist delamination. If the project succeeds, aircraft manufacturers could cut weight and assembly costs while improving structural integrity. The same technology could transfer to automotive production, where lighter body panels mean better fuel efficiency. The project also develops the predictive software and quality-control methods needed to certify these woven parts for safety-critical use. The immediate impact is on manufacturing supply chains. The UK currently lacks the capability to design, simulate, and produce 3D woven composite components at scale. This project aims to build that end-to-end process, from digital design tools to factory-floor weaving machines, strengthening the domestic supply chain for next-generation composite structures.