INJECTION/OVERMOLDING

Injection/Overmolding

Bespoke process produces composite brake pedal every minute

Three composite materials are used to create structural composite member that meets demanding mechanical requirements.

Peggy Malnati
Contributing Writer

Injection/Overmolding

Thermoplastic composite structure replaces metals on safety-critical brake pedals

First all-composite brake pedals developed by Boge Rubber & Plastics Group are lighter, stiffer, stronger and offer improved driving haptics.
#focusondesign #composites4_0

Carbon Fibers

Clean Sky 2 IMCOLOR project develops integrated manufacturing process for lightweight product design

Multi-shot injection molding process and thermoplastic automated fiber placements with in-situ consolidation for automated, easy-to-reproduce parts that perform at high mechanical levels.
#cleansky

Injection/Overmolding

Altair Inspire Mold simulates injection molding process to optimize manufacturability

Inspire Mold can evaluate manufacturability of new components at the outset of development, complete design iterations faster, reduce cost and other optimization features.

Automotive

SGL Carbon, Koller Kunststofftechnik manufacture composite windshield

Injection molded carbon fiber profiles for future BMW Group models cut 40% of weight compared to conventional steel construction and offer potential use in other automotive projects. 
#bmw

Overmolded hybrid parts open new composites markets

Overmolded hybrid parts open new composites markets

A process that combines continuous carbon fiber-reinforced PAEK with chopped fiber/PEEK overmolding is making inroads in the aerospace market. Parts that previously could not be produced cost-effectively from composites can now be made at less cost than their metal counterparts.
#insidemanufacturing #layup #paek

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Videos / Podcasts

Carbon Fibers

Conbility: Mass production of composite tape laminates

RWTH Aachen spin-off scales up production for low-cost, in-situ consolidated composites as inserts for lighter, cheaper injection-molded parts.
#composites4_0 #continuousfiberAM #trends

Carbon Fibers

Proving out LM PAEK welding for Multifunctional Fuselage Demonstrator

Clean Sky 2 STUNNING project will manufacture lower thermoplastic fuselage while MECATESTERS will test Toray LM PAEK in conduction and induction welding for parameters, cyclic loading, aging and environmental effects .
#nextgenaerospace #ndi #cleansky

Defense

Magnetic 3D printing the next generation of tailored composites

Fortify uses magnetic fields and digital light processing to produce tailored microstructures for high-resolution, 3D printed composite parts — and enables the next generation of multiscale, multifunctional composite metamaterials.
#pei #uas #ceramicmatrixcomposites

Additive Manufacturing

Sustainable, inline recycling of carbon fiber

Shocker Composites and R&M International are developing a supply chain for recycled CF with zero knockdown vs. virgin fiber, lower cost and, eventually, lengths delivering structural properties close to continuous fiber.
#sustainability #discontinuousfiber

Automotive

Molding in fasteners to CFRP parts

Placed into the mold prior to RTM, compression or injection molding/overmolding, this specially-shaped fastener enables composites to be fastened with standard methods used for metal parts.
#outofautoclave #cuttingtools

Thermoplastics

JEC World 2018 preview: Tri-Mack Plastics

Tri-Mack Plastics Mfg Corp. is sharing the results of a recently completed test that demonstrates the bond strength of Tri-Mack’s overmolded thermoplastic composite hybrid parts.
#marketing #adhesives

Design/Simulation

Preforming goes industrial: Part 1

ATL and AFP-based preforming options now abound for processing dry and/or impregnated reinforcements as quickly as 1 minute or less with potential yearly part yields in the millions.
#camx #bmw #feature

Carbon Fibers

Clean Sky 2 IMCOLOR project develops integrated manufacturing process for lightweight product design

Multi-shot injection molding process and thermoplastic automated fiber placements with in-situ consolidation for automated, easy-to-reproduce parts that perform at high mechanical levels.
#cleansky

Carbon Fibers

SGL Carbon, Koller Kunststofftechnik manufacture composite windshield

Injection molded carbon fiber profiles for future BMW Group models cut 40% of weight compared to conventional steel construction and offer potential use in other automotive projects. 
#bmw

Prepregs

AVK announces winners of 2020 Innovation Awards

Several sustainable composite innovations were recognized and awarded in the Innovative Products/Applications, Innovative Processes and Research and Science categories.
#automation

Injection/Overmolding

Aviation research program kicks off for continuous complex composite profiles

InPro project combines blow molding technology with Continuous Compression Molding (CCM) process for efficient, sustainable continuous composite profile production.  
#peek #boeing

Glass Fibers

BASF, Toyota collaborate for 2021 Sienna lightweighting

The 2021 Toyota Sienna features third row free-standing seatbacks and a 30% weight reduction with BASF’s 35% glass-reinforced polyamide PA6 grade Ultramid.
#trends #toyota

Injection/Overmolding

Composites feature in Altair’s 8th Annual Enlighten Awards

Recognized jointly with the Center for Automotive Research (CAR), winners represent the world’s best initiatives to reduce vehicle weight and meet emissions targets.
#toyota #sustainability #generalmotors

NEW PRODUCTS: INJECTION/OVERMOLDING

Injection/Overmolding

Altair Inspire Mold simulates injection molding process to optimize manufacturability

Inspire Mold can evaluate manufacturability of new components at the outset of development, complete design iterations faster, reduce cost and other optimization features.

Injection/Overmolding

KraussMaffei recompounding line available for customer trials

Applicable for extrusion and injection molding, the line enables all post-consumer LDPE, HDPE, PP or PS fractions to be processed into recompounds.
#sustainability

Injection/Overmolding

Engel launches forming and functionalization of organic sheets

Production cell demonstrates the forming and functionalization of organic sheets and unidirectional tapes in one injection molding step.
#sustainability

Infusion

Composite Integration launches resin transfer molding, infusion technologies

The company’s modular infusion manifold automates the infusion process to simplify manufacture of large composite structures.
#outofautoclave #regulation

Pultrusion

JEC World 2019 preview: KraussMaffei

KraussMaffei (Munich, Germany) is focusing on its FiberForm process, pultrusion and unidirectional (UD) tapes at its JEC World 2019 booth, Booth R28, Hall 6.
#outofautoclave

Thermoplastics

JEC World 2019 preview: Engel

At JEC World 2019, Engel Austria is presenting its technologies for organomelt processing, in-situ polymerization, HP-RTM and flow molding with SMC.
#sheetmoldingcompound #hprtm #audi