Lightweight Design

The fabrication of components from organic sheets with glass, carbon or polyamides reinforcing fibres is increasingly gaining importance, especially in lightweight Design. We develop single-stage manufacturing processes for the economical production of fibre matrix semi-finished goods in cooperation with partners.

Unidirectional (UD) tapes are thermoplastic composites with continuous filament reinforcement. They are used to selectively reinforce high-stress zones on components. Tailor-made organic sheeting produced this way can be processed as injection moulding inserts and for structural components with a high load bearing capacity.

Natural fibres such as hemp, sisal, coconut, jute, flax and other renewable raw materials are increasingly being used in composite materials (NFRCs) for ecological reasons and based on their characteristics. They replace glass or carbon fibre reinforcing materials for example. Processed into mats or felt, they are used as preliminary products for press-moulded parts which in turn can be overmoulded or back-injected. Applications include numerous interior trim components in vehicle construction such as rear panel shelves, boot linings or interior door cladding.

Expanded polypropylene (EPP) is a thermoplastic granulated foam plastic with densities from 15 to 80 kg/m³, very good mechanical properties, a high energy absorption and thermal insulating capacity, and tremendous lightweight construction potential. EPP components are not produced with a propellant but with steam. In combination with granulated foam composite injection moulding®, foamed moulded parts can be permanently joined with plastic. The components fuse at their boundary surfaces, creating a strong material bond that is also recyclable. 

The MuCell process consists of physical foaming on an injection moulding machine or extruder. A gas (nitrogen or CO2) in a hypercritical state is used as the propellant, injected directly into the plastic melt. Plastification turns this into a homogeneous single-phase solution. Material and weight savings of up to 20% and more are possible in this way. Additional benefits include shorter cycle times, reduced closing forces and numerous other advantages. Combined with variotherm tool temperature control, the process is now also suitable for the production of components with high-quality surfaces.