INJECTION/OVERMOLDING

Pultrusion

German consortium develops biopolymer-based Cellun composite

German Institutes of Textile and Fiber Research (DITF) and partners present a conventional composite material alternative using cellulose that can be processed using industrial processing methods.

Grace Nehls
Managing Editor, CompositesWorld

German consortium develops biopolymer-based Cellun composite
JEC World 2023 preview: KraussMaffei
Pultrusion

JEC World 2023 preview: KraussMaffei

KraussMaffei is featuring a variety of technologies, including Fiberform, resin transfer molding, structural component spraying, pultrusion and more.
#outofautoclave

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Mass Transit

JEC World 2023 preview: Engel

Engel’s organomelt process as a single integrated production cell for thermoplastic composite production demonstrates high production efficiency and low unit cost for aerospace and automotive.  
#automation #jec #peek

Automotive

Seat frame demonstrates next-generation autocomposites design

Light weight, simplified/cost-effective manufacturing, passenger comfort and safety informed materials and process innovations and won awards for the 2022 Toyota Tundra‘s second-row seat frame.
#electricvehicles #focusondesign

Design/Simulation

Jeep all-composite roof receivers achieve steel performance at low mass

Ultrashort carbon fiber/PPA replaces steel on rooftop brackets to hold Jeep soft tops, hardtops.
#focusondesign

Overmolded hybrid parts open new composites markets

Overmolded hybrid parts open new composites markets

A process that combines continuous carbon fiber-reinforced PAEK with chopped fiber/PEEK overmolding is making inroads in the aerospace market. Parts that previously could not be produced cost-effectively from composites can now be made at less cost than their metal counterparts.
#insidemanufacturing #wingoftomorrow #space

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Additive Manufacturing |

Robotized system makes overmolding mobile, flexible

Anybrid’s ROBIN demonstrates inline/offline functionalization of profiles, 3D-printed panels and bio-based materials for more efficient, sustainable composite parts.
#sustainability #workinprogress

Ginger Gardiner Senior Technical Editor, CompositesWorld

Videos / Podcasts

Bcomp and KTM Technologies natural fiber brake disc cover
Epoxies

Thermoset-thermoplastic joining, natural fibers enable sustainability-focused brake cover

Award-winning motorcycle brake disc cover showcases potential for KTM Technologies’ Conexus joining technology and flax fiber composites.
#sustainability #biomaterials #focusondesign

Carbon I MK II smartphone
Construction

CFRTP enables better, greener smartphones

Carbon Mobile’s “monocoque” design eliminates separate case, cover and frame, better protects electronics and simplifies disassembly.
#focusondesign #sustainability

Sensors: Data for next-gen composites manufacturing
Injection/Overmolding

Sensors: Data for next-gen composites manufacturing

In the quest for sustainability, sensors are reducing cycle times, energy use and waste, automating closed-loop process control and increasing knowledge to open new possibilities for intelligent manufacturing and structures.
#sensors #windblades #SHM

stamp-forming cell at Victrex Composites Solutions
Urban Air Mobility

Plant tour: Victrex Composites Solutions, Bristol, Rhode Island, U.S.

De-risking thermoplastic composites at industrial scale via hybrid overmolding.
#wingoftomorrow #space #outofautoclave

Robotic injection molding for functionalized composites
Injection/Overmolding

Robotic injection molding for functionalized composites

Anybrid enables compact, flexible hybrid injection molding/overmolding for smaller series and larger components.
#trends #automation

ENLIGHTEN program launched to speed thermoplastic composites industrialization
Testing

ENLIGHTEN program launched to speed thermoplastic composites industrialization

Multi-scale modeling, testing, sensors and machine learning will advance understanding and algorithms to achieve process control and optimization for both aerospace and automotive supply chains.
#paek #composites4-0 #wingoftomorrow

AZL Aachen Ultra-Fast Consolidator Machine
Consumer

Conbility: Mass production of composite tape laminates

RWTH Aachen spin-off scales up production for low-cost, in-situ consolidated composites as inserts for lighter, cheaper injection-molded parts.
#composites4-0 #continuousfiberAM #trends

Mass Transit |

Automotive chassis components lighten up with composites

Composite and hybrid components reduce mass, increase functionality on electric and conventional passenger vehicles.
#electricvehicles #feature

Peggy Malnati Contributing Writer
Composite truck component carrier from Lanxess wins GKV/TecPart Innovation Award
Automotive

Composite truck component carrier from Lanxess wins GKV/TecPart Innovation Award

  Injection-molded glass fiber-reinforced PA6 component is jointly developed with system supplier and truck manufacturer for 35% less weight, replaces DLFT-based design.  

Covestro, Arcesso Dynamics launch solid-surface manufacturing solution Arfinio
Injection/Overmolding

Covestro, Arcesso Dynamics launch solid-surface manufacturing solution Arfinio

First use of reaction injection molding (RIM) on aliphatic polyurethanes enables complex, lightweight and seamless designs and new property combinations.  

9T Labs, Purdue University to advance composites use in structural aerospace applications
Additive Manufacturing

9T Labs, Purdue University to advance composites use in structural aerospace applications

Partnership defines new standard of accessibility to produce 3D-printed structural composite parts as easily as metal alternatives via Additive Fusion Technology, workflow tools.  
#bulkmoldingcompound #continuousfiberAM #workforcedevelopment

Automotive

Toyota Tundra composite seatback design awarded 2022 Altair Enlighten Award

BASF, Flex-N-Gate, L&L Products and Toyota limited an all-steel assembly, cutting 60 parts down to four composite pieces for 20% weight savings.  

Design/Simulation

SABIC, Dongfeng Motors produce composite truck-mounted toolbox

Thermoformed glass fiber-reinforced PP laminate inserts are overmolded with Stamax resin for a 30% lighter part.

Thermoplastics

Tepex composite opens up new opportunities for electric skateboards

The continuous fiber-reinforced thermoplastic is used for a trough-shaped skateboard deck application, notable for its high torsional and bending strength, light weight and moisture protection.

Thermoplastics |

TU Munich develops cuboidal conformable tanks using carbon fiber composites for increased hydrogen storage

Flat tank enabling standard platform for BEV and FCEV uses thermoplastic and thermoset composites, overwrapped skeleton design in pursuit of 25% more H2 storage.
#hydrogen #trends

Ginger Gardiner Senior Technical Editor, CompositesWorld

NEW PRODUCTS: INJECTION/OVERMOLDING

Xenia Thermoplastic Specialties launches new range of supertough carbon fiber composites
Injection/Overmolding

Xenia Thermoplastic Specialties launches new range of supertough carbon fiber composites

New XECARB ST family of carbon fiber-reinforced thermoplastic composites combines advanced lightweighting with superior impact strength.

Porcher Industries launches new range of flax fiber-based thermoplastic composites for automotive
Automotive

Porcher Industries launches new range of flax fiber-based thermoplastic composites for automotive

Composite stiffeners, sold as textiles, are made primarily of flax fibers grown, selected, mixed and woven in France for modern, durable and environmentally conscious applications.  

Altair Inspire Mold simulates injection molding process to optimize manufacturability
Injection/Overmolding

Altair Inspire Mold simulates injection molding process to optimize manufacturability

Inspire Mold can evaluate manufacturability of new components at the outset of development, complete design iterations faster, reduce cost and other optimization features.

KraussMaffei recompounding line available for customer trials
Injection/Overmolding

KraussMaffei recompounding line available for customer trials

Applicable for extrusion and injection molding, the line enables all post-consumer LDPE, HDPE, PP or PS fractions to be processed into recompounds.
#sustainability

Engel launches forming and functionalization of organic sheets
Injection/Overmolding

Engel launches forming and functionalization of organic sheets

Production cell demonstrates the forming and functionalization of organic sheets and unidirectional tapes in one injection molding step.
#sustainability

Composite Integration launches resin transfer molding, infusion technologies
RTM

Composite Integration launches resin transfer molding, infusion technologies

The company’s modular infusion manifold automates the infusion process to simplify manufacture of large composite structures.
#outofautoclave

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