Underside of a maintenance access hatch for passenger aircraft, showing the injection moulded features and ribs over the compression moulded organo sheet. In a single process, developed by Engel, a pre-heated thermoplastic organosheet is loaded into the mould cavity and over-moulded with high temperature thermoplastic. The materials are carbon fibre polyaryletherketone (PAEK-CF) organo and polyetheretherketone (PEEK) injection mould.
Relevant materials
Carbon fibre (CF), T300, Standard modulus, high tensile (HT), 1K, 3K, 6K and 12K tow
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Aerospace, Automotive, Carbon fibre, Compression moulded, Engel, High temperature thermoplastic, Injection moulded, Organo, Polyetheretherketone (PEEK), Product, Sports, Super fibre, Thermoplastic composite
Cross-section through the detachable roof modules of the Ford Bronco. This part is made with a thermoformed thermoplastic outer layer, which is back-moulded with glass fibre and polyurethane resin (PUR), plus a Nomex honeycomb core for increased thickness (stiffness with minimal additional weight). It is manufactured by compression moulding, whereby the thermoformed polycarbonate (PC) is placed into the mould, onto which glass fibre and honeycomb are laid. A precise dose of PUR is applied by spraying on the layers and then the whole assembly is compressed in a mould and heated to cure.
Relevant materials
Polyurethane resin (PUR), PUR, Plastic Aramid fibre (AF), PMIA, M-aramid, Nomex, Polymetaphenylene isophthalamide Polycarbonate (PC), PC, Engineering plastic, General purpose
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Aramid, Automotive, Composite, Compression moulded, Honeycomb, Laminated, Nomex, Plastic, Polycarbonate (PC), Polyurethane resin (PUR), Thermoformed
An electric vehicle battery pack tray injection compression moulded in long glass fibre reinforced polypropylene (PP-LGF20) by Engel to demonstrate their large-format insert moulding capabilities.
Relevant materials
Polypropylene (PP), PP-LGF20, Moulded composite, 20% long glass fibre
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Automotive, Composite, Compression moulded, Engel, Glass fibre, Injection moulded, Lightweight automotive, Plastic, Polypropylene (PP)
Cross-section through a concept automotive seat by Johnson Controls and Camisma, manufactured with a combination of thermoforming and injection moulding. Sheets of continuous and unidirectional 12k carbon fibre and in-situ cast PA12 are combined with powder impregnated PA12 nonwoven recycled carbon fibre. They are placed into the mould and thermoformed, prior to back injection moulding of the rib structure using 30% long glass fibre filled PA12. Compared to a steel equivalent this structure saves 50% of the weight.
Relevant materials
Polyamide (PA), PA-GF30, bio-PA, Nylon 12, 30% glass fibre Carbon fibre (CF), T300, Standard modulus, high tensile (HT), 1K, 3K, 6K and 12K tow Polyamide (PA), PA12, bio-PA, Nylon 12, Resin
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Automotive, Bio-based plastic, Carbon fibre, Composite, Compression moulded, E-glass, Furniture, Injection moulded, Lightweight automotive, Organo, Polyamide (PA), nylon, Super fibre, Technical textile, Thermoplastic composite, Unidirectional
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