Greene Tweed and Arrow McLaren Jointly Develop Lightweight Racing Components

Greene Tweed collaborates with Arrow McLaren to design a lightweight anti-roll bar lever using Xycomp DLF thermoplastic composite material for the NTT IndyCar Series race cars.

High-performance materials manufacturer Greene Tweed partnered with Arrow McLaren to co-develop a lightweight anti-roll bar lever using advanced thermoplastic composite technology. The redesigned component reduces each car’s weight by 64 grams while meeting the strength and reliability requirements of top-tier open-wheel racing.

The anti-roll bar lever is a key component in the suspension system, responsible for suppressing body roll and maintaining handling balance during high-speed cornering. In IndyCar racing, cars often exceed speeds of 220 miles per hour, and performance improvements are measured in milliseconds; even slight reductions in weight and optimizations in mechanical balance can lead to more stable handling, tire management, and driving stability.

Greene Tweed worked closely with the engineering team at Arrow McLaren to assess the performance requirements, geometry, manufacturing methods, and material needs of the component. They subsequently changed the design from a 7075 aluminum alloy billet to Xycomp DLF. This high-performance thermoplastic composite boasts an outstanding strength-to-weight ratio and is specifically designed to replace complex metal parts in aerospace, defense, industrial, and other demanding applications.

“The collaboration with Arrow McLaren provided an excellent proving ground for Xycomp DLF. In this application, converting a complex-shaped suspension component from a well-established aluminum billet design to a thermoplastic composite—and having it perform reliably under the extreme stresses of IndyCar racing—required deep collaboration and a high degree of trust,” said Sebastien Kohler, Senior Scientist at Greene Tweed. “By leveraging the properties of DLF composites, we not only reduced weight, but also validated an entirely new design and manufacturing approach in one of the most demanding racing environments.”

Greene Tweed partnered with McLaren to develop lightweight anti-roll bar levers for the team’s NTT IndyCar Series race cars using Greene Tweed’s Xycomp DLF thermoplastic composite material. (Image source: Greene Tweed)

Engineering collaboration drives innovation

The partnership between Arrow McLaren and Greene Tweed is a technology partnership focused on identifying opportunities through integrated engineering support. The development and application of a new anti-roll bar lever using Greene Tweed’s Xycomp DLF thermoplastic composite material is a clear example of the value of this collaborative model.

The Xycomp DLF anti-roll bar leverage ratio was first installed on Nolan Siegel’s No. 6 car at Barber Motorsports Park, and was subsequently rolled out across all Arrow McLaren cars. Beginning with the historic Long Beach Grand Prix in April, the component was deployed on all of Arrow McLaren’s entries.

In addition to the material change itself, this project also highlights the value of Greene Tweed’s deep involvement in the redesign and manufacturing process, significantly reducing the internal development burden on Arrow McLaren’s engineering and production teams. As an integrated engineering partner, Greene Tweed was involved throughout the design, material selection, and manufacturing process optimization to meet performance requirements, rather than serving merely as a supplier.

The core of this project is to replace the original 7075 aluminum alloy anti-roll bar lever with compression-molded Xycomp DLF while maintaining the same structural performance requirements.

The key role in high-performance racing cars

The anti-roll bar system is a key mechanical device in an IndyCar suspension assembly. Its primary function is to suppress body roll during cornering by transferring load between the left and right suspension assemblies.

In open-wheel race cars with high downforce, vehicle balance is greatly influenced by the distribution of roll stiffness. Adjustments to the front and rear roll stiffness directly affect tire load transfer, corner-entry stability, mid-corner balance, and traction on corner exit.

The stiffness and durability of the anti-roll bar are crucial for maintaining consistent handling performance over a full high-mileage season. Their role is especially pronounced on ultra-high-speed circuits such as the Indianapolis 500.

At the Indianapolis Motor Speedway, cars race at high speeds, with average speeds exceeding 220 miles per hour, and each corner endures continuous lateral loads. Under these conditions, even slight changes in mechanical balance can have a significant impact on tire wear, aerodynamic stability, and overall balance during the 500-mile race.

“Greene Tweed has exceeded all expectations. Their expertise in materials, manufacturing processes, and the performance requirements we faced made the development and production of this component extremely smooth,” said Kory Drake, Design Engineer at Arrow McLaren. “Their team demonstrated deep technical understanding and a collaborative spirit throughout the project, resulting in a true engineering partnership. We greatly value this relationship and look forward to working together for many years to come.”

Xycomp DLF is a high-performance thermoplastic composite material designed to replace metal components and withstand extreme operating conditions, offering a lightweight solution. (Image source: Arrow McLaren)

Material Selection and Manufacturing Advantages

The team ultimately chose Xycomp DLF—a high-performance thermoplastic composite—as a lightweight solution to replace metal components, capable of withstanding extreme conditions. When Greene Tweed switches parts to this material, a weight reduction of typically 35% can be achieved, making it highly attractive.

Arrow McLaren evaluated in-house manufacturing options but recognized that Greene Tweed offered a unique and valuable path through its expertise in scaled production and mature composite material applications. Through deeper technical engagement, Greene Tweed helped validate the value of Xycomp DLF for anti-roll bar levers, building strong confidence in its performance and durability.

Greene Tweed’s role is not only that of a material supplier, but also that of an integrated technical partner throughout the entire development cycle. Achieving all objectives requires not only material innovation, but also the collaborative efforts of Arrow McLaren and Greene Tweed.

Through a comprehensive collaborative review and by comparing real-world operating conditions, confidence was strongly reinforced that this composite material can meet the requirements of the anti-roll bar lever in terms of load-bearing, durability, and environmental performance. Greene Tweed’s combination of materials expertise and manufacturing capabilities ultimately made the solution stand out, proving it to be the ideal choice to meet fleet needs.

Performance Impact in a Competitive Environment

Although the weight reduction may appear modest in absolute terms, lightweighting remains an important performance advantage in the NTT IndyCar Series, where the competitive environment is highly constrained and the cars are largely standardized. The final design successfully incorporated the benefits of Xycomp DLF material technology while meeting all operational requirements.

Greene Tweed is a global leader in the manufacturing of high-performance thermoplastics, composites, seals, and engineered components. Its products deliver superior performance and long-lasting durability in the world’s harshest environments. For 160 years, the company has served industries where mistakes are not an option, including semiconductors, oil and gas, aerospace, defense, chemical processing, and pharmaceutical processing. Greene Tweed products are sold worldwide.