Portfolio

Mapping the complete production chain for fibre composite components

The thermoPre® portfolio includes various textile reinforcement structures, partly and fully consolidated fibre-reinforced prepegs, robust multiple layer composites, new technologies, innovative machines, sample components, expertise in the field of calculating and design work, but also compact, interdisciplinary expertise along the complete value-added chain.

Fibre-reinforced thermoplastic pre-pegs

Textile reinforcement structures with single-dimensional (rovings) or multi-dimensional designs (textile fabrics) are used to produce the new thermoPre® prepegs. Hybrid structures with an integrated thermoplastic matrix can be processed too. All the reinforced fibre types like glass, carbon, aramid and basalt fibres and all the thermoplastic mass and high-performance plastics can be used.

Technical parameters of thermoPre® material GF 47-PP-UD

Semi-finished product, unidirectional prepreg Features
Fibre type E-glass fibre
Polymer Polypropylene (PP)
Fiber volume content 47 %
Single-layer thickness 0,20 mm
Mechanical properties of the unidirectional structure Fiber direction Transverse fibre direction
Tensile modulus 34,8 GPa 5,4 GPa
Tensile strength 865 MPa 19 MPa
Compressive strength 380 MPa 45 MPa

Fields of application

Applications in all industrial fields are conceivable for the new thermoPre® material. They range from crash-relevant components in the automobile industry to assembly units for wind turbines and even interior panelling parts for railway vehicles. Continuous fibre-reinforced thermoplastic prepegs are particularly suitable for components subject to high levels of stress. The new prepegs offer plenty of potential to achieve the necessary breakthrough for enhanced usage in all fields of industry.

The following summary illustrates the benefits of components with the thermoPre® material compared to parts made of classic materials.


Component Production from classical materials Advantages of using the thermoPre® material
Engine mounting for VW e-Golf Aluminium casting with steel sheet fixtures (weight: approx. 7.7 kg)
  • Weight savings of up to 35%
  • Cost savings of up to 30%
  • Greater energy absorption in a crash – no abrupt component failure
  • Almost the same rigidity performance
Component Production from classical materials Advantages of using the thermoPre® material
Pressure container for commercial vehicles Steel
  • Approx. 46% weight savings
  • Designed for high operation pressure
  • Simple production with small rebuild outlay
Component Production from classical materials Advantages of using the thermoPre® material
Car door impact absorber Steel
  • Approx. 10% weight savings
  • Same performance
  • ntegrating a damage recognition system in the manufacturing process to detect any component failure in a crash

The single-stage direct processing method

The new type of technology concept of single-stage direct processing, i.e. processing “in a single heating procedure”, constitutes a good option compared to the previous method of manufacturing prepegs. Traditional, conventional processes are much more complex and energy-intensive.

“Affordable lightweight design” from direct processing

The separated process stages are combined in the thermoPre® method to offer a single-stage direct manufacturing system. This provides significant reductions in production costs and the prepegs too. Compared to conventional technology, the new machine includes the following features:

  • High process variability regarding the technical/technological process parameters
  • High degree of flexibility for the input systems needing to be handled (textile reinforcement structures, matrix)
  • Modular, flexible design with automated interfaces to process stages upstream and downstream
  • Up to 30% energy savings in the direct manufacturing process
  • Several heating stations, which can be separately controlled (pre-heating line and calendar heating)
  • Separated impregnation and cooling process and therefore separately controllable with a small overall size

Robust organic sheeting using the “contitaping” process

Robust multi-layer composites (organic sheets) are made from several layers of continuous fibre-reinforced thermoplastic thermoPre® prepegs using the “contitaping” process. Depending on the desired thickness of the organic sheet, it is possible to vary both the number of thermoPre® prepegs and the angular position too. This creates a robust and highly rigid structure.

Advantages

  • Coupling the load-specific layer design to single-stage direct manufacturing to provide a complete process chain from the fibre to the organic sheet
  • High throughput in the continuous process
  • Flexibility in the layer structure (freely selectable, symmetrical and asymmetrical)
  • Low machine costs
  • Minimal need for space

The modular structure

The modular structure illustrates different opportunities for creating a multi-directional, multi-layer structure from unidirectional, fibre-reinforced, thermoplastic, individual layers. Depending on how the prepegs are used later (organic sheets), other layer structures are possible.

Flexible components and new ideas for your production too

Are you interested in individual modules for single-stage direct manufacturing or are you planning the overall production? The thermoPre® network is happy to support you in drawing up the design of your machines so that they are fully tailored to your requirements.

Contact us! We will be happy to send you a quotation.