Commingled continuous thermoplastic tow yarns support wide application range

Concordia Engineered Fibers (Coventry, R.I., U.S.) has specialized in the development of engineered yarns since 1920, maintaining a long history of innovation as a specialist in advanced twisting, precision winding and yarn conversion. Prior development successes include twisted carbon fiber for 3D woven preforms, conductive fibers for antistatic fabrics and PTFE fibers for greaseless bearings. As an ISO 9001-certified company, Concordia prides itself in the variety of industrial applications that have used its yarns over the decades. The company notes that its ability to process dozens of input fiber types is especially pronounced in the development of commingled yarns.

Concordia’s continuous tow containing customized ratios of reinforcement fibers with thermoplastic fibers produces flexible thermoplastic prepregs especially designed for use in advanced thermoplastic composites. This intimate blending of dissimilar fibers in a continuous filament format lends itself to a wide range of industrial, aerospace and sporting good applications. Concordia’s PEEK and PPS commingled yarns have been used in a variety of aerospace applications, while nylon, PET and polycarbonate commingled yarns have been used in consumer products including tennis racquets, bike frames and hockey sticks.

According to the company, processing of commingled continuous tow is not limited to standard layup practices. Use of the commingled fiber in thermoplastic pultrusion, for example, is reported to overcome the challenge of high-viscosity plastics. The thermoplastic is already in place where it is needed, no resin infusion bath needed. In addition, pultrusion can create an input filament for 3D printing, and the commingled yarn has the capability of being used as a direct input with customized sizing.

Concordia’s commingled materials have also been used in tailored fiber placement (TFP), where continuous fibers are stitched onto a substrate. The customized geometry enables the creation of near-net-shape preforms, thus greatly reducing waste. Other solutions including filament winding, braiding, 3D printing and weaving. 

Concordia provides an international footprint, with facilities in France, Mexico and at its headquarters in Rhode Island.

Concordia CEO, Sean Reymond, will be speaking at the CAMX “Fiber Forms Improving Product Manufacturability and Performance” panel on Wednesday, Nov. 1, 2023 at 3:30 p.m.