THERMOPLASTIC COMPOSITES | MATERIALS
Easier to process than thermosets, thermoplastic composites are finding new applications in key markets such as automotive. Mark Holmes reports on new developments
Composites ingenuity leads to automotive uptake
Thermoplastic composites are rapidly becoming a viable alternative to thermosets. A thermoplastic matrix can be reinforced with long fibres and manufactured with a variety of additives to offer a wide range of properties. Advantages of thermo- plastic composites include low weight, high mechanical strength and ease of manufacture through injection moulding in short cycle times. They can also be combined with other materials to make hybrid structures and, unlike thermosets, are easily recyclable, offering sustainable solutions in the circular economy. The market for materials substitution is increas-
ing for reasons of mobility, resources and sustain- ability, and thermoplastic composites are a perfect base material for these applications, according to Arburg. “Depending on the application and the requirements there are several solutions,” says Manuel Wöhrle, lightweight construction expert at Arburg. “One solution is to use long-fibre materials,
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as well as combinations with continuous reinforced fibres. The [Arburg] Fibre Direct Compounding (FDC) process enables inline compounding on an injection moulding machine. It is possible to improve the mechanical properties of the compo- nent, especially strength and toughness, while saving material costs. One further benefit is that the material can be customised to the application. The fibre length, fibre content and material combination can be selected to match specific needs. In addi- tion, recycled materials can be used. The next step to improve mechanical properties is to overmould continuous reinforced fibre materials. These can be organosheets, tapes or a combination.” He says: “The right combination of materials is needed to achieve the necessary solution to substitute other materials. A successful substitution will only be possible with a holistic approach. It is not only necessary to focus on weight reduction, but also consider improving the mechanical
Main image: Lightweighting and part integration are two of the attractions of thermoplastic composites
January/February 2021 | INJECTION WORLD 27
IMAGE: SHUTTERSTOCK
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