KS Composites, a UK-based manufacturer with nearly four decades of motorsport heritage, has enhanced its advanced manufacturing capabilities through the implementation of OPEN MIND Technologies’ hyperMILL CAD/CAM solution. The Melton Mowbray company, which serves elite racing series including Formula 1 and Le Mans, selected the modular software to optimize its CNC machining operations across both composite and metallic materials.
This strategic investment supports KS Composites’ position as a turnkey provider of high-performance composite solutions, from initial design through to final production. The company’s expertise spans multiple sectors including motorsport, renewable energy and defense, where precision composite components are increasingly in demand.
Tailored Software Solution for Diverse Manufacturing Needs
The hyperMILL system’s modular architecture allows KS Composites to precisely configure the software to its specific requirements, accessing advanced 5-axis machining capabilities without unnecessary features. “We identified hyperMILL as the optimal solution during our evaluation of CAM packages following our facility expansion,” explained Dan Johnston, Business Development Manager.
The software’s efficiency gains are particularly valuable for the company’s prototype and low-volume production work, where rapid programming turnaround is critical to meeting tight motorsport development timelines. OPEN MIND’s Justin Tallboys-Cotton noted the company’s ability to select only the required modules provides cost-effective scalability for future needs.
From Crisis to Cutting-Edge Facility
Following a devastating fire in 2018 that destroyed its Long Clawson premises, KS Composites relocated to a significantly larger 48,000 sq ft facility in Old Dalby. The reconstruction presented an opportunity to modernize operations, with CNC machinery and the hyperMILL system forming central components of the new production environment.
This upgraded infrastructure enables the company to handle complex projects spanning carbon composite body panels, machined GRP components, and additive manufactured elements. The expanded space and advanced equipment have allowed KS Composites to consolidate operations that were previously spread across multiple locations.
Streamlining Motorsport Manufacturing Processes
OPEN MIND’s Justin Tallboys-Cotton highlighted how KS Composites has implemented sophisticated software features including color-coded components and template systems. These operational improvements standardize programming workflows across its team while reducing programming time significantly.
The company maintains the extreme precision required for motorsport applications, where component tolerances directly impact vehicle performance. Recent projects have demonstrated the system’s capabilities in creating show vehicles and race components with exceptional surface quality and dimensional accuracy.
Delivering Precision for Performance-Critical Applications
The partnership underscores the evolving technological demands of modern motorsport manufacturing and adjacent high-tech industries. “When creating show vehicles or race components, we’re representing the pinnacle of precision engineering,” Johnston emphasized.
The hyperMILL system has proven particularly valuable for pattern-making applications, where surface quality and dimensional accuracy are paramount. As KS Composites continues to serve elite clients while expanding into new markets, its investment demonstrates commitment to maintaining technological leadership in high-performance composite manufacturing.
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