AGN Composites represents a benchmark of excellence in carbon fibre engineering and the wider field of composite materials. Established with the aim of producing high-performance components, the company has developed into a trusted name within motorsport, aerospace and specialist engineering sectors.
Origins and Evolution
Founded in 2017, AGN Composites began with a clear mission to integrate design, manufacturing and repair services under a single roof. From the earliest days, the company set out to do more than simply fabricate parts: it intended to master the entire engineering lifecycle. This involves everything from initial CAD design through pattern and mould construction, fabrication and testing to delicate repairs and the reverse engineering of damaged components.
Over the years the company has earned the confidence of clients across motorsport, automotive, aerospace, marine and industrial markets. Its reputation has been built on consistent quality, technical innovation and the ability to meet the rigorous standards demanded by championship teams and safety regulators.
Core Competencies and Services
AGN Composites provides a comprehensive range of services that form the backbone of its success.
Design and Engineering
From concept sketches to fully fledged CAD models, the company excels in precision design. Engineers collaborate with clients to ensure that every component meets strict requirements for strength, weight, aerodynamics, thermal resistance and regulatory compliance. Reverse engineering is a key part of the process: when only a damaged part remains, AGN can create technical drawings or 3D scans, rebuild moulds and reproduce parts to the original or even improved specifications.
Mould, Pattern and Tooling Manufacture
Mould making is a specialist discipline that AGN masters with care. The team produces high-precision moulds from durable materials to guarantee repeatability and tight tolerances. Patterns for composite layups are created meticulously to control fibre orientation, thickness and surface finish. Tooling is also developed in-house, tailored to specific geometries and load paths, ensuring that the production process runs efficiently.
Composite Production
The company handles the full spectrum of composite production techniques. Pre-preg layups involve storing carbon fibre pre-impregnated with resin under controlled conditions and then curing it in autoclaves to achieve high strength and minimal voids. Wet layups are used for larger or less weight-sensitive parts, applying vacuum bagging and resin infusion to maintain correct fibre resin ratios. Resin transfer moulding enables the rapid production of more complex shapes. Every step is subject to rigorous quality control to ensure straight fibre orientation, minimal void content and a consistently high surface finish.
Repair and Restoration
Composite repairs are among AGN’s strongest specialities. When a component is damaged in a motorsport crash, through weather exposure or from fatigue, the company can assess the damage, de-laminate and rebuild the affected areas and restore the structural integrity. When original specifications are unavailable, AGN can reverse-engineer the part from damaged samples to reproduce the required form and function.
Industries Served
AGN Composites’ expertise is in demand across several demanding sectors.
Motorsport
Motorsport is a harsh testing ground with its high stresses, rapid fatigue and uncompromising safety standards. The company supplies body panels, aerodynamic components, structural parts and safety equipment to racing teams. Its ability to create light yet strong parts and to repair crash damage swiftly provides teams with critical performance and logistical advantages.
Automotive and Performance Vehicles
Performance and specialist road vehicles also benefit from AGN’s skills. Lightweight body kits, reinforcing panels, custom carbon fibre interiors, diffusers and spoilers are all engineered for durability, aesthetics and performance.
Aerospace and Defence
The strength-to-weight benefits of composites are essential in aerospace. AGN produces components where regulatory compliance, fatigue life and precision are critical. The company offers traceable material certification, structural testing and environmental durability for aviation and defence applications.
Marine and Industrial
Marine craft require composites that withstand moisture, salt and UV exposure. AGN produces hull components, panels and fixtures designed to perform in these conditions. In industrial settings, composite parts are used in machinery, tooling and jigs where strength, light weight and chemical or thermal resistance are vital.
Key Technologies and Materials
AGN Composites uses advanced materials and techniques to maintain high standards and drive innovation.
High-Grade Carbon Fibre
A variety of weave patterns are selected depending on stiffness, drapeability and aesthetics, including plain weave, twill weave and unidirectional cloths. High modulus fibres provide exceptional stiffness while intermediate modulus fibres balance cost and performance.
Resin Systems
Epoxy resins dominate because of their toughness, adhesion and thermal resistance. For specific applications, thermosetting vinyl esters or phenolics may be chosen. UV-stable resins are used for external parts to prevent yellowing and degradation.
Autoclave and Curing Technology
Autoclave curing achieves high fibre-volume fractions, reduces voids and delivers superior mechanical properties. Vacuum bagging and post-curing are equally important for controlling resin flow, cure kinetics and dimensional accuracy.
Non-Destructive Testing and Quality Assurance
Safety and performance require stringent checks. AGN employs ultrasonic inspection, dye penetrant testing and laminate thickness measurement to detect delamination, voids and bonding issues. Dimensional checks guarantee that moulded parts meet geometric tolerances.
CAD/CAM and Digital Workflow
The company uses 3D scanning for reverse engineering, solid modelling tools for design and CNC machining for pattern and mould making. Data-controlled processes ensure that repeat productions are consistent and traceable.
Competitive Strengths and Differentiators
Several factors set AGN Composites apart in the market. It provides full lifecycle capability from design through manufacture, repair and reverse engineering, eliminating the need for multiple vendors. Its motorsport pedigree demonstrates the ability to work under demanding deadlines and high-performance conditions. Attention to detail extends beyond structural integrity to the surface finish and paint readiness of every component. Customised tooling and moulds are manufactured in-house, reducing lead times and improving the fit and finish of parts. A robust quality management system with thorough checks at every stage and advanced inspection techniques ensures exceptional reliability.
Challenges in the Composite Industry and How AGN Meets Them
The composite industry presents several challenges that AGN is well equipped to handle.
Material Costs and Supply Chain
Carbon fibre, resins and tooling materials can be expensive and subject to supply fluctuations. AGN counters this by maintaining strong supplier relationships, purchasing in bulk and engineering alternative materials where performance allows.
Lead Times Against High Demand
Motorsport projects demand rapid turnaround. AGN employs agile workflows, prioritised scheduling, modular tool sets and buffer stocks of essential consumables to meet tight deadlines.
Environmental and Regulatory Demands
Composite manufacturing involves chemicals, waste and high energy usage. AGN addresses these issues by adopting low-VOC resins where possible, containing and treating resin waste and using energy-efficient curing methods. The company stays ahead of regulatory changes in aerospace and automotive standards.
Repair Complexity
Irregular damage patterns require custom lamination and exact matching of fibre orientation and resin properties. AGN’s reverse engineering capabilities and experienced staff allow the repair of even complex parts while restoring original strength.
Case Study in Motorsport Crash Repair
Racing teams frequently experience body or chassis component damage during events. AGN Composites provides a rapid response. Clients deliver the damaged part or share detailed images or scans. AGN assesses the structural and cosmetic damage, performs 3D scanning if geometry is missing, prepares the surface and removes damaged laminate. Technicians reconstruct the part with matching fibres, cure the repair, finish and polish the surface and finally inspect it for structural integrity and appearance. This process restores parts to race-ready condition and helps teams avoid costly replacements.
Sustainability and Environmental Responsibility
The composite industry is scrutinised for its environmental impact. AGN Composites recognises the challenge and is exploring recyclable and bio-based resin systems, methods to refurbish or reuse composite tools and moulds, and ways to reduce waste fabric and trimming. The company also investigates more energy-efficient curing cycles. While full recyclability is not yet achievable, AGN shows awareness and forward planning.
Future Prospects
The future holds significant opportunity for AGN Composites. The rise of electric vehicles will increase the need for lightweight, high-strength parts to offset battery weight. The company is well placed to serve this market. Hybrid materials, nanomaterial-enhanced resins and novel fillers are likely to feature in advanced composites. The synergy of additive manufacturing and 3D printing with traditional composite layup can improve speed and reduce cost. A growing market for composite repair and refurbishment aligns with AGN’s strengths, while international collaboration offers scope for expansion.
Key Considerations for Clients
Clients looking to work with AGN Composites should define requirements clearly, specifying strength, stiffness, finish, weight, environmental exposure and lifecycle needs. Allowing for prototyping helps identify unforeseen challenges, and understanding lead times is crucial, as custom moulds and curing processes take time. While high-performance composites may cost more than conventional materials, the gains in weight reduction, strength and longevity often justify the investment.
Conclusion
AGN Composites has established itself as a leader in carbon fibre and composite component fabrication, repair and design. Its complete lifecycle capability, technical excellence and motorsport-honed quality make it a preferred partner for clients seeking high-performance, precision parts. With the industry increasingly focused on lightweight construction, sustainability and stringent performance standards, AGN is well positioned to remain at the forefront of composite engineering.
