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Composites |


year. It allows long fi bre reinforced (LFT) materials to be produced on the injection moulding machine by incorporating glass fi bres of lengths of up to 50mm directly into the plasticising system. At K, the process is demonstrated overmoulding LFT


onto a Tepex continuous fi bre reinforced thermoplastic composite sheet from Lanxess to produce a 500mm long structural part weighing just 200g. The production system will be running on an energy-optimised hydraulic Allrounder 820 S machine with servo-hydrau- lic drive using an LIPA (Lightweight Integrated Process Application) mould from Georg Kaufmann. A six-axis robot, integrated by FPT Robotik, is used to pick and load the thermoplastic composite sheets in the preheating station, to place them into the mould, and to remove the fi nished parts. The fl at sheet insert is gently heated to the required


processing temperature using a new technology in the gripper system and then transferred to the LIPA mould, where it is formed to a W-shaped profi le and functional and reinforcing elements such as edging, mounting bosses and ribbed structures are injection moulded in LFT. The entire cycle takes around 40s.


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According to Arburg, by ensuring the temperature of


the organic sheet is above the melting point of the matrix resin a perfect mechanical bond is achieved with the overmoulded component. Arburg sees this composite processing technology


fi nding applications in lightweight structural members such as automotive seating frames. The company says its direct long fi bre thermoplastic technology is a good


Above: Lanxess engineers examine a


composite door beam produced by overmould- ing a formed sheet


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