Only a few fibers thick and thinner than a human hair, A+ Composites GmbH’s (Weselberg, Germany) new generation of thin-ply unidirectional (UD) tapes target new standards in thermoplastic composites (TPC). Designed with high-performance matrix systems such as polycarbonate (PC), polyamide 12 (PA12), polyamide 6 (PA6) and polyphenylene sulfide (PPS), these tapes enable the production of very lightweight, durable and recyclable components.

With individual ply thicknesses below 50 µm and fiber volume contents of up to 68%, the tapes enable precise laminate construction and high structural performance. Each tape is engineered with a smooth surface and features an integrated thin polymer top layer. This added layer, says A+ Composites, accelerates welding and consolidation during processing, making these thin-ply tapes faster to process than conventional UD tapes, which is ideal for high-throughput production environments.

The tapes are optimized for use in automated processes such as automated fiber placement (AFP), automated tape laying (ATL) and also Fiber Forged Technology. Their drapability and optimal surface quality reduce voids and ensure high optical and mechanical part quality with minimal postprocessing.

Thanks to their thin-ply construction, these tapes are ideal for ultra-thin structures with, for example, total laminate thicknesses under 300 µm of a five-ply layup — well suited for applications in high-performance sports equipment and aerospace parts, and functional components in consumer electronics, where weight, thickness and mechanical integrity are critical. They also bring with them the inherent benefits of thermoplastic matrices — such as fast cycle times, weldability and impact resistance.

The tapes are available with a wide range of fibers, like AGY S2 glass fiber or carbon fibers — high-tenancy, intermediate modulus, ultra-high tenacity and high modulus carbon fibers. A+ Composites can also customize to customer needs.