Render of a Formula car

YCOM Full Vehicle: 15 Years of Perfecting the Program

An expert in delivering full vehicle programs for motorsport, high-performance road cars, and niche mobility applications, YCOM is trusted by OEMs around the world to bring ideas into reality.

Whether initiated by OEMs or pitched by YCOM to OEMs, full vehicle programs always begin with one thing – an idea. Whether it’s taking on the fastest class of endurance racing at Le Mans or challenging for a hill climb record, the YCOM team are behind some of motorsport’s most successful and high-profile vehicle programs.

YCOM’s Full Vehicle offering is the result of its 15 years’ experience at the forefront of racing. It is a level of engineering, production, testing, racing and commercial know-how that makes even the most ambitious and complex ideas possible. Understanding how a program will evolve, where to utilize the budget, and meeting performance targets are all areas that have been mastered over two decades at the forefront.

The YCOM Approach

At the centre of YCOM’s continued success is its holistic approach to engineering and development. It is an understanding of interrelated systems and the fundamental requirements to achieve specific outcomes. In some cases, the ability to deliver a program in an extremely short timescale, within budget, and maximising performance, has only been possible with YCOM’s level of experience and in-house capabilities.

“If, for example, a company comes to us asking for a racing program, we already have a significant understanding of what is required and insight into how it can be achieved,” explains Marco Merlin, YCOM Project Management Director. “We understand the rules and homologation requirements, know the level of performance required to be competitive in the field, know how such a program evolves and progresses, can optimize the timescales, know where to allocate budget for the best possible product and – importantly – maximise performance for the OEM.”

The accelerated timescales of most full vehicle programs mean that YCOM can take a project from initial concept to first test in just 6-12 months, depending on the requirements. Throughout the entire process, YCOM’s team is in constant communication with the customer and any external suppliers, aligning all of the ‘moving pieces’ to meet program objectives.

Marco Merlin, YCOM Project Management Director
Integrated & In-house

YCOM’s greatest strength is the ability to fulfil all program requirements on-site. It operates a fully integrated facility that can execute the entire full vehicle process from the initial idea and design through to vehicle production and race-day trackside support. Enabling its services is a passionate staff working across all business functions, with up to 60% dedicated to engineering service.

The need for high-performance composites means that YCOM has a commercial-scale composite department, with a large autoclave that can produce parts as large as monocoques, aero floors, and bodywork. This is complemented by a machine shop capable of CNC machining parts as large as 4x4m.

It is having also been a pioneer in advanced natural fibre composites – an increasingly effective solution to help decarbonize motorsport and passenger vehicles.

Vehicles come together in dedicated assembly bays.

“We have everything in the same facility, fully integrated, end to end,” continues Marco Merlin. “This plays a significant role in our success, with open and ongoing internal communication that allows us to oversee and drive every aspect of the program. Feedback loops are shortened, engineers are more ‘hands-on’, and we can quickly alter part and system designs in line with our testing.”

The company has ISO 9001 and ISO 14001 certifications, alongside FIA Three-Star Environmental Accreditation. During the COVID-19 pandemic, YCOM took the opportunity to overhaul the sustainability of its facility and processes.

The YCOM Process

Over the years, YCOM has refined its internal processes and project stages to deliver the best possible outcome for customers. Each step of the process is outlined below:

  1. Concept: Create the project idea and business plan. Establish timing, cost, and performance targets, while also defining the team and leadership of the program.
  2. Design: Engineering and simulation, looping between the two for optimization.
  3. Procurement and Manufacturing: Component designs are finalized, and the first prototypes are created from CAD. Integrated facilities allow for quick validation and re-designs, where required. For the components that cannot be produced in-house, YCOM utilizes an extensive short-range, motorsport-focused, supplier network.
  4. Quality control: YCOM’s in-house quality control facilities ensure that all components meet application-ready requirements.
  5. Bench Validation: Components and sub-systems are tested to ensure performance prior to assembly.
  6. Assembly: The prototypes are assembled in YCOM’s bays with meticulous attention to detail.
  7. Track validation: track validation are conducted by the in-house Track Team (race engineer, mechanics, data engineer). The Track Team meets with the design and engineering team after each test session, further optimizing the vehicle.
  8. Series production: Once the prototype is validated and the customer gives the ‘green light’, series production begins. Before being sent to the customer, each car has a one-day shakedown.
  9. Support: YCOM provides on-track support for many programs, including race-day trackside support for international series.


Throughout all processes, we usually conduct weekly internal meetings with all project members, weekly supplier meetings, and weekly updates with the customer.

Conclusion: An Industry Reference

After fifteen years of perfecting full vehicle programs, YCOM has evolved into one of the most respected companies in the industry and is trusted by some of the world’s largest OEMs. The company’s holistic approach – combining engineering expertise, efficient program management, and comprehensive in-house capabilities – allows it to rapidly deliver complex vehicle projects that fulfil target outcomes. It has achieved this across the entire motorsport spectrum, from entry-level series through to the highest level of endurance racing, as well as select automotive and mobility projects. As the company looks towards the next two decades, its well-proven methodology will continue to deliver impressive results for its customers.

If you would like to learn more about YCOM’s offering, please get in touch.

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