Formula 1 (F1) Visa Cash App Racing Bulls (VCARB) and Holy Technologies (Hamburg, Germany) have successfully completed an 18-month joint R&D project to demonstrate the potential of Holy’s Infinite Fiber Placement (IFP) technology. The project achieved optimal results, resulting in the manufacture of an existing component of VCARB’s 01 race car with 20% weight reduction while ensuring it is fully recyclable (learn more about the project here).

This collaboration has led to the development of a fully recyclable wing mirror housing that is said to not only meets the rigorous quality standards required for F1, but also achieves significant weight reduction compared to traditional manufacturing methods. This achievement underscores the commitment of both companies to push the boundaries of automotive engineering, while addressing environmentally responsible practices.

Unlike conventional methods that rely on prepreg materials with pre-aligned fibers, Holy Technologies’ approach uses a single, robotically placed carbon fiber strand embedded into a recyclable epoxy resin, enhancing the structural integrity and recyclability of the component. This process also enables the separation of the epoxy from the carbon fiber for its reuse in the same high-performance application.

“Holy Technologies is taking a different approach to the manufacturing process that is normally used for carbon fiber components” says Paolo Marabini, chief designer at VCARB. “It opens up the opportunity to reuse the same carbon fiber and therefore has the potential to significantly reduce the overall amount of material we use for our car components, while at the same time optimizing the performance of those components.”

Bosse Rothe Frossard, CEO of Holy Technologies, says that the work with VCARB shows how its IFP platform helps customers realize the full potential of their design while still enabling small- and large-series production with high efficiency.

The technology was tested during a Grand Prix to demonstrate its use in the harsh environments common to a motorsport race weekend. Both companies plan to continue exploring further innovations in sustainable manufacturing.