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1/30/2017 | 1 MINUTE READ

Evonik develops new PulPress process for mass-production of molded composite parts

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The company says that molded parts made using PulPress will soon be going into mass production.

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Evonik (Essen, Germany) says that its newly developed PulPress method allows manufacturers to mass-produce complex molded parts at a reasonable price, taking the technology from the high-end market to large-scale production. 

PulPress combines two traditional production techniques: compression molding and pultrusion. Combined together, they make automated, continuous production of composite parts possible. The most important raw material in the process is ROHACELL, a high-performance structural foam core from Evonik, according to the company. Fibers are woven around the core before being impregnated with resin. The complete system is then compressed into the desired shape at high temperature and pressure. The method even allows manufacturers to produce complex geometries and integrate recessed areas for threaded components or other fixtures. 

Evonik claims that some highlights of the new manufacturing process include its design flexibility and cost efficiency, and the crash behavior of the resulting composite parts—parts that are around 75 percent lighter than traditional steel structures. In addition, the PulPress method also reportedly reduces costs by up to 60 percent compared to composite parts manufactured using established methods such as resin injection. “These advantages have already won over a large number of customers in the European automotive industry,” Sivakumara Krishnamoorthy, manager for new applications in Evonik’s Resource Efficiency Segment. “Molded parts made using PulPress will soon be going into mass production.” 

The process could also be applied in aircraft construction as a cost-effective method for producing large numbers of carry-over parts as well as in sports equipment applications. 

Evonik will showcase this PulPress method at JEC World (March 14 – 16, in Paris, Hall 5A, H44). 

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