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.
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.
Vekrun performance bike saddle base structure is injection moulded with Lehvoss Luvocom polyamide 610 (bio-PA) combined with recycled carbon fibre (rCF).
A high impact transportation case for delicate electronics injection moulded with polyamide 66 plus 30% glass fibre (PA-GF30). The coarse sparked surface texture helps to conceal the visual impacts of the glass fibres.
Polyamide 6 (PA), nylon, from recycled scrap. The colour that can be achieved in recycled plastic depends on the source of waste. In this case, Kolon produce recycled PA from old ship mooring ropes, the core of which provides a relatively clean source of material suitable for bright colours. If mixed waste is used, light bright colours are not usually possible, unless sophisticated sorting is employed to separate white and clear from coloured, which increases cost.
A power tool housing injection moulded in 30% glass fibre reinforced polyamide 6 (PA-GF30). A combination of additives and surface texture help to conceal the visual impact of the fibres.
Injection over-moulded die cast aluminium for a Hilti power tool gearbox body. The aluminium is cast and de-burred, and the polyamide (PA-GF30), nylon, is over-moulded in-line using a fully automated process developed by Frimo.
Audi loud speaker grille made with LYB LyondelBasell CirculenRecover 50% post industrial recycled (PIR) acrylonitrile butadiene styrene blended with polyamide (rABS-PA). It has properties very close to that of virgin polymer for this application.
The Noho Move dining chair by Noho is injection moulded from Econyl recycled polyamide (rPA), nylon, along with recycled polypropylene (rPP). Image Econyl.
Door impact bar test part for the Audi A4 consisting of several layers of woven glass fibre in a polyamide (PA-GF), nylon, matrix. The PA-GF organo is thermoformed into the shape of the mould and then back injection moulded with short fibre PA-GF. The result of a collaboration between Audi AG, Bond Laminates, the Institute for Composite Materials, Jacob Plastics, Lanxess, and KraussMaffei, this is a mass-producible composite suitable for safety-critical automotive applications. It is known as SpriForm and FiberForm.
Nike Mercurial football boot made with Bond Laminates Tepex, a carbon fibre reinforced thermoplastic polyurethane (TPU) sole plate, injection over-moulded with polyamide (PA), nylon.
Hope Forever Blossoming portable folding vase, by D-Bros, 2003, in multi-layer laminated polyethylene (PE), polyester (PET) and polyamide (PA), welded to form a water-tight stand-up container
Thermoplastic polyamide elastomer (TPA), nylon, film raincoat. The type of nylon exhibits a high moisture vapour transmission rate (MVTR), and so provides an alternative to PFAS-containing breathable fluoropolymer membranes, like Gore-Tex, for example.
Eames Plastic Armchair DAL, designed by Charles & Ray Eames for Vitra, 1950, features nylon hopsack woven fabric on a glass-fibre reinforced polypropylene (PP-GF) shell
Woven laminated airbag made with polyamide (PA), nylon, fibre and a fluid silicone coating. Alternatively, an impermeable film is laminated onto the nylon fabric to help maintain air pressure when inflated. The seams are welded for maximum resistance to tearing.
Commingled glass fibre thermoplastic composite preform, fabricated through tailored fibre placement (TFP) - a type of technical embroidery - in preparation for moulding with heat and pressure
Launched as part of the Stella McCartney Spring 2023 collection, this parka is made with 100% Econyl recycled polyamide (PA), nylon. At the end of its useful life it can be taken back and fully recycled by Aquafil, the manufacturer of Econyl. Image Aquafil / Stella McCartney.
Tarkett carpet tiles produced from Econyl regenerated polyamide (PA), nylon fibre. It is recycled in a closed loop process, by turning nylon waste from old carpet tiles into new floors.
Econyl regenerated polyamide (PA), nylon fibre, from old carpet, spun into yarn in preparation for weaving into new Tarkett carpet tiles. Together, Aquafil and Tarkett have created a closed loop recycling process.
Messenger bag, made with Cordura fabric, which is woven with a high-strength polyamide (PA), nylon. Nylon provides an extremely hardwearing and weatherproof outer, resistant to dirt, abrasion and tearing.
Hyundai front bumper crash beam development, manufactured by CQFD using curved reactive thermoplastic pultrusion (CRTP) of continuous glass fibre reinforced nylon 6 (PA-GF), overmoulded with glass fibre reinforced black PA-GF
A composite panel made up of UDX PPA and UDX PA11 unidirectional carbon fibre tapes impregnated with bio-sourced and recyclable thermoplastic resins. These two types of polyamide (PA), nylon, composites are produced by Arkema. The random mix has been formed using the quick press process developed by ICC (Japan).
A lightweight shovel made with in-situ polymerised and injection moulded polyamide (PA), nylon. In a process developed by Engel, a woven glass fibre preform is infiltrated with caprolactam and reacted to form a thermoplastic composite. This semi-finished part is transferred to an over-moulding tool and the green parts applied by injection moulding.
A lightweight shovel made with in-situ polymerised and injection moulded polyamide (PA), nylon. In a process developed by Engel, a woven glass fibre preform is infiltrated with caprolactam and reacted to form a thermoplastic composite. This semi-finished part is transferred to an over-moulding tool and the green parts applied by injection moulding.
Injection moulded thermoplastic composite FCS H4 surf fin. It is produced by Svismold with unidirectional thermoplastic tape acting as skins, sandwiching a moulded thermoplastic core. With this technology, it is possible to combine several different types of fibre reinforcement and thermoplastic matrix, resulting in different levels of performance. This examples is unidirectional glass fibre and polyamide (PA-GF), nylon.
Cross section of thermoplastic pultruded composite box beam, by CQFD, made up of unidirectional glass fibre and in-situ cast nylon 6 (PA-GF) used for construction
Cross section of thermoplastic pultruded composite, by CQFD, made up of unidirectional glass fibre and in-situ cast nylon 6 (PA-GF) suitable for construction and automotive applications
Injection moulded thermoplastic composite FCS H4 surf fin. It is produced by Svismold with unidirectional thermoplastic tape acting as skins, sandwiching a moulded thermoplastic core. With this technology, it is possible to combine several different types of fibre reinforcement and thermoplastic matrix, resulting in different levels of performance. This example is basalt fibre and polyamide (PA-BF), nylon.
Positive Plastics injection moulded sample of Omnix Recycle 50% glass fibre reinforced polyamide (rPA-GF50). This is a high performance material used in metal replacement that bridges the gap between lower performing PA grades and higher performing and higher cost polyphthalamide (PPA).
Cross-section through the frame of the Affenzahn pushbike made with glass fibre reinforced polyamide (PA0-GF), nylon. The lightweight hollow frame is made using water injection technology (WIT). Similar to gas injection, during the moulding cycle, water is injected, forming a bubble inside the molten plastic, pushing it into the mould cavity and forming a hollow core. It is made with coloured PA, so not pigment is required in the paint layer, and reduces the visible damage from surface scratches. The cut plastic has been painted black for this sample to show off the technology.
Detail of Kinematics dress, by Jessica Rosenkrantz and Jesse Louis-Rosenberg for Nervous System, is 3D printed in polyamide (PA), nylon powder. All the parts are printed together, pre-assembled with integrated hinges, creating a flexible articulated structure. Photo Nervous System.
Detail of Hyphae 3D #1, by Jessica Rosenkrantz and Jesse Louis-Rosenberg for Nervous System, is 3D printed in polyamide (PA), nylon powder. Photo Nervous System.
Detail of Florescence Crispata, by Jessica Rosenkrantz and Jesse Louis-Rosenberg for Nervous System, is 3D printed in polyamide (PA), nylon powder. Photo bNervous System.
Bergo Extreme interlocking floor tiles, injection moulded in UV-resistant polyamide (PA), nylon, offer slip resistance in areas such as passenger balconies, pool areas, laundry rooms, engine rooms and freezer rooms on yachts, ferries and cruise ships.
Prototyping in Tokyo exhibition, Japan House London, 2019, featuring bio-inspired work of Professor Yamanaka Shunji and his lab at the University of Tokyo, made with selective laser sintered (SLS) nylon powder
Press-formed automotive part, made up of patches of continuous glass-fibre reinforced nylon PA6, orientated to optimise strength, manufactured using Cetim’s high-speed thermostamping technique, named Quilted Stratum Process (QSP)
Press-formed automotive part, made up of patches of continuous glass-fibre reinforced nylon PA6, orientated to optimise strength, manufactured using Cetim’s high-speed thermostamping technique, named Quilted Stratum Process (QSP)
Commingled glass fibre thermoplastic composite yarn, fabricated through tailored fibre placement (TFP), compression moulded to form a composite shoe sole
Cross-car beam produced by Elring Klinger with thixomoulded magnesium alloy assembled onto hydroformed aluminium alloy, over-moulded with 60% glass fibre reinforced polyamide (PA-GF60), nylon. This type of hybrid metal construction provides maximum strength to weight, whilst allowing design freedom for the integration of instrument panel, steering, airbags, hot and cold air, and all other necessary elements.
KTM Technologies motorcycle brake cover. It consists of a pre-formed epoxy flax composite panel, made with Bcomp's ampliTex, combined with an injection moulded polyamide 6 (PA6), nylon trim.
Compression moulded composite Wilson bat, produced from embroidered glass fibre reinforced polyamide (PA), nylon, preform. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Compression moulded composite wheel hub and rim, produced from embroidered glass fibre reinforced polyamide (PA), nylon, preform, over-moulded with PA. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Compression moulded composite wheel hub reinforcement, produced from embroidered glass fibre reinforced polyamide (PA), nylon, preform. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Embroidered glass fibre reinforced polyamide (PA), nylon, preform for a Wilson bat. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Compression moulded composite, produced from embroidered glass fibre reinforced polyamide (PA), nylon, preform. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Embroidered glass fibre reinforced polyamide (PA), nylon, preform. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Cross-car beam produced by Elring Klinger using hydroformed aluminium alloy, over-moulded with 60% glass fibre reinforced polyamide (PA-GF60), nylon. This type of hybrid metal construction provides maximum strength to weight, whilst allowing design freedom for the integration of instrument panel, steering, airbags, hot and cold air, and all other necessary elements.
Positive Plastics injection moulded samples of Akromid Next 30% glass fibre reinforced polyamide 5,10 (PA-GF30). This grade of PA is 100% bio-based made from corn starch and castor oil.
Spot Material is a database of materials for sustainable design, curated by Rob Thompson. Compare properties, carbon and end of life, find better alternatives and discover new material innovations. Browse all materials
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