NAA Member News: Prestigious contract to design precision valve springs for next generation of Cosworth engines in multi-million pound hypercars drives success of Force Technology
Growth of Blackpool-based business supports multi-billion pound commitment to advanced engineering and manufacturing (AEM) sector in Lancashire Growth Plan.
World class specialist provider of precision springs Force Technology is manufacturing valve springs for globally renowned engine designer and manufacturer Cosworth to use in the next generation of hypercars.
The prestigious contract is one of a number involving the firm’s valve springs being used in a wide range of high-performance supercar and racecar engines, including globally recognised automotive and motorsport brands.
Northampton-based Cosworth is the undisputed global leader in hypercar engine design, with 68 years of heritage and experience to develop engines that push the boundaries of performance, while also adhering to ever-stricter global emissions regulations.
Rare, multi-million pound hypercars are the peak of automotive engineering, featuring cutting-edge materials, extreme aerodynamics and hybrid or electric engines that often exceed 1,000 horsepower and capable of speeds of 250mph to 300 mph.
Based at Lightworks, Shorebury Point, Amy Johnson Way, Blackpool, Force Technology employs 50 specialist staff and sells its precision valve springs to customers worldwide. The business was co-founded in 2015 by managing director Steve Williams following a long career in advanced engineering manufacturing.
As well as providing valve springs for supercars and racecars, Force Technology also manufactures them for huge engines used in cruiseliners, container ships and airliners and markets including locomotives, motorcycles, construction and mining vehicles and historic and classic vehicles.
Steve said: “We’re growing at a great pace nationally and internationally and Lancashire is a great place to do business as an advanced engineering and manufacturing business.
“Every valve spring we produce is fully bespoke to the customer’s application. Development programmes can take many months – and in some cases several years – as we work closely with customer design engineers to optimise spring performance using advanced engineering tools such as Finite Element Analysis (FEA).
“Once a design is established, the springs progress through a rigorous multi-stage sampling and validation programme. This ensures both manufacturing quality and in-engine performance, with extensive durability and functional testing carried out before production approval.”
On the springs produced for Cosworth, he explained: “In a modern high-speed engine, the valve spring plays a critical role in controlling the movement of the valve train under extreme forces and dynamic vibration.
“At very high engine speeds, maintaining precise valve control is essential to ensure efficient combustion, maximum performance, and long-term reliability. Our challenge is to engineer valve springs capable of controlling and damping these forces in some of the world’s most demanding operating conditions.”
Steve stressed that Force Technology sources only premium-grade spring wire for its spring valves – because even microscopic material defects can have a significant impact on fatigue life and may ultimately result in catastrophic engine failure – with manufacture of a high-performance spring valve potentially involving more than 20 production stages.
Every completed spring batch passes through a comprehensive final inspection and quality validation process and when required, springs can also be tested on Force Technology’s in-house engine spin test rig.
If material is available and in stock, Steve said typical manufacturing lead times range from four to eight weeks.
Developed by the Lancashire Combined County Authority (LCCA) and championed by the Lancashire Business Board (LBB), comprising members of the county’s leading regional, national and international businesses, the Lancashire Growth Plan identifies transformational projects in five high-growth business sectors including advanced engineering and manufacturing (AEM) with the potential to attract more than £20bn of additional public and private investment.
Together, these projects could create thousands of jobs and strengthen Lancashire’s role at the heart of the national economy.
Prof. Miranda Barker OBE, spokesperson for Lancashire Business Board, said: “Lancashire’s advanced engineering and manufacturing sector contributes about £6.4bn to the local economy and includes key industries such as aerospace, energy, chemicals and commercial vehicles.
“Force Technology’s prestigious contract with Cosworth and its other high value customers in the UK and worldwide reflects the AEM sector’s resilience, innovation and global competitiveness, playing a critical role in driving productivity, exports, and sustainable growth.”
