So, you want to be an F1 Composite Design Engineer?
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Stronger, lighter and thus faster, composites – and in particular carbon fibre – have been at the heart of F1 performance for more than 40 years. And with up to 85 per cent of an F1 car now made from them, the work of a team's composites engineers is hugely important. So, what exactly do they do and how do you pursue a career in this field? Junior Composite Design Engineer Abbie Croker reveals all…
From its earliest days, Formula One has had a focus on weight-saving. Forever seeking to lighten the load hauled around a track in pursuit of more pace and better laptimes, teams have obsessively shaved off the kilos through the use of material such as aluminium, titanium and magnesium.
However, in 1981 the game changed completely with the arrival of the first F1 monocoque made entirely of carbon fibre. Strong, rigid, and most importantly incredibly light, carbon fibre revolutionised F1 car design to the point that aside from the engine and gearbox, almost all of a current F1 is made from the wonder material – and if it's not carbon fibre it will be one of a host of similar materials such as Zylon, aramids, and polyethylene filaments.
It all means that composite designers are highly prized by Formula One teams. But what exactly do they do and how do you become one? It's a question we put to Junior Composite Designer Abbie Croker, who reveals that the road to the cutting edge of materials science isn't necessarily the ultra-rarefied route you might imagine...
This job really matters because composites are the car
"As a Junior Composite Designer, I am responsible for designing composite parts using CAD and making the parts from surfaces. By 'surfaces' I mean the 'shell' given to us by the aerodynamics department and we turn those shells into parts on the computer. We make sure those parts go together with the ones around it, as part of an assembly, and that might be any part of the car.
"The entire shell of the car features composites of some kind. From the chassis to the front wing and the rear wing, which is the part of the car I focus on, to the floor, which is really important to the aerodynamics of the car, all of it is composites. We also look after the parts once they're made. So if a part breaks on track the race team come back to us to ask whether that part can be kept and repaired or should no longer be used."
You're always developing something, modifying something to make the car better and faster.
Abbie Croker, Junior Composite Design Engineer
You will be involved with every part of the team
"The composites department is connected to everyone in the team. When it comes to producing a new part, we start by talking to the aerodynamics department, but after that we speak with the structures team, they decide how strong the parts need to be to survive on the car, all while keeping it as light as possible, and then in composites we do the final design. That design then goes to laminating. Once that's done, it goes to the trim shop, which assembles the composite components. Then the part then goes to inspection. We are in constant dialogue and collaborating with all the different people in these respective parts of the team, even the team trackside if something goes wrong and they need a quick solution."
It can be intense
"The pace of the job can be relentless at times. You're always developing something, modifying something to make the car better and faster. The pressure is on all the time. There are occasional quiet periods, but most of the time it's a case of, 'You need to get this done by the end of the day.' It's relentless and you have to be prepared for that.
"But, in some ways, that's the most enjoyable part of the job, because when you see the part you've worked on take to the track – and it doesn't break – all the hard work and effort feels worth it. You get a real sense of accomplishment. It definitely feels like an achievement because you're looking at a part you worked on and thinking, 'I've put time into this car and that time is now coming back – a lot,' and that's a lovely thing. There's the competitive side to things as well. If you see the car and the parts you've worked on contribute to a performance gain, it makes you feel proud about what you've achieved and the journey you went on to deliver that performance."
Experience is something we look for. And we're looking for people with a real interest in the sport.
Abbie Croker, Junior Composite Design Engineer
Carbon fibre can be beautiful
"There's a certain beauty in the structure of carbon fibre. It looks so fragile and yet it has such strength. Some of the parts we produce are about a millimetre thick, some even thinner, and yet they stay on the car going around a track at 200mph. That's definitely beautiful!"
Take the road less travelled
"My career path and route to the team was slightly unusual. I started with an apprenticeship at Aston Martin Lagonda. It was a degree-level apprenticeship, so I got to do my engineering degree and that was for four years. I did about six weeks at university each year and the rest of the time I was working full-time. And that was actually in car interiors, so completely different to what I'm working on at Aston Martin Aramco!
"I'd never actually worked in composites before joining the team, which is the reason why I started in a junior role – because I wanted to learn something new. I wanted a challenge and I really wanted to work in F1 because it's so fast-paced. In the automotive industry you wait for months to get parts through and here it's the next day!"
"I would encourage people to take apprenticeships, not necessarily over university, but at least consider them, because if you're more practical-minded – which I definitely am, I learn better from actually doing things – then an apprenticeship really allows you to get stuck in and you kind of forget you're studying."
I'm proud to play my part by doing anything I can to inspire the next generation of female engineers.
Abbie Croker, Junior Composite Design Engineer
Experience counts
"We're looking for people who have studied or have experience in STEM-related subjects. Typically, candidates will have at least a Bachelor's degree. It's not essential, but it's usually the minimum requirement. A lot of teams make a point of wanting candidates to have a Master's degree, but that isn't necessarily always needed.
"I only have a Bachelor's degree, but because I went through the apprenticeship route, I had a wealth of experience that helped to set me apart from other candidates. Experience is something we look for. And we're looking for people with a real interest in the sport. It's not all about academic studies.
"Sometimes it can almost look impossible to pursue a career in F1 because every aspect of a team is performing at such a high level and its operations are so advanced – just reaching that level seems like a huge mountain to climb. But it's not impossible. I would encourage anyone to go for it. Just look at me, I came from a completely different part of the industry.
"Just because you don't have absolutely everything required in the job description, doesn't mean you can't apply for it. In an ideal scenario, you would tick all the boxes on the job spec, but the reality is no one will ever have everything. So, 100 per cent, you've just got to go for it. And don't get disheartened if your application is unsuccessful, or even many applications. It's unlikely you will walk straight into an F1 team. Perseverance is key!"
Mastercraft
So, you want to be a Composite Design Engineer?
Abbie Croker discusses what's required to pursue a career as an F1 Composite Design Engineer.
"As a woman coming into an engineering organisation, especially when I was starting my apprenticeship when I was one of only three girls out of 30 people, it did feel odd and I felt out of place a little bit – but not anymore.
"Historically, there hasn't been enough female representation in the sport, and I love going back to my old school to speak to the students. Every time I go back, I see more girls in STEM subject classes than the year before. Hopefully, the students see that I've made it to F1 and that I've pursued a career in engineering, and it gives them the belief that they can also make it into the sport.
"When we have schools visit us at the AMR Technology Campus, about 20 per cent of the students are female rather than just a handful. The number of girls showing an interest is growing and that's very exciting. And I'm proud to play my part by doing anything I can to inspire the next generation of female engineers.
"At Aston Martin Aramco, we're passionate about increasing diversity, equality and inclusion throughout the industry and beyond. As long as you've got the talent and the right attitude, there's a place for you in our team."
Top tips
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Apprenticeships are a great way to learn and gain practical experience.
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A Bachelor's degree in a STEM subject is often the minimum requirement for a Composite Design Engineer.
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Experience gained in other industries can be transferable to the role.
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Perseverance is key.
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