Composites
composite materials can be used to produce lightweight components with optimal mechanical properties, excellent resistance to degradation and high corrosion resistance.
The versatility in designing complex shapes and the outstanding performance of composites provide a series of significant advantages for various applications in sectors such as aerospace, construction, automotive, naval, sports, among others.
AIMPLAS has the knowledge and technology your company needs to develop high added value materials, products and processes.
- Resin transfer processes: mould design and sensor implementation in moulds to optimise the RTM process.
- Pultrusion: selection of materials, product design, validation in a pilot plant, application of UV-cured coatings and application of gel-coat on the production lines.
- Compression processes: obtaining prototypes, selection of raw materials to meet final product specifications and the development of biocomposites.
- Solid surface: improvement of properties by developing formulations and incorporating nanoparticles.
- Non-conventional curing of thermosetting resins: microwave and UV radiation. Adaptation of this technology to different processing types: RTM, infusion, pultrusion, etc.
- Polyurethane foaming.
- Flame retardancy of polymer matrices.
- Biocomposites: adaptation of production processes and optimisation of properties.
- Recovery of end-of-life tyres and other thermosetting polymers by developing new manufacturing processes.
- Chemical characterisation of thermosetting matrices.
- Physico-mechanical characterisation of thermoset composites.
- Recyclability studies and reuse of waste thermosetting materials.
- New technologies and improved processes for occupational safety.
Innovations in Thermoplastic Composites and Multifunctional Doped Thermoplastic Composites
AIMPLAS, as a pioneering centre in the research and development of these materials, provides innovative solutions that meet the demanding requirements of the mobility sector:
UD-tapes
UD-tapes, or unidirectional tapes, are strips of reinforcing fibres, typically glass or carbon, arranged in a single direction and impregnated with thermoplastic resin. AIMPLAS has developed and optimised a production line for manufacturing these thermoplastic tapes using melt impregnation techniques, achieving competitive quality and consistency in the final product. Unidirectional tapes can be deposited using various automated deposition technologies, such as Automated Fibre/Tape Placement (AFP or ATP), through the In-Situ Consolidation (ISC) technique. These tapes are ideal for applications requiring high strength in a specific direction, such as structural components in the aeronautics industry.
Dry Fibre
In addition, AIMPLAS has created a production line to obtain dry fiber through the impregnation of continuous reinforcement with thermoplastic matrices using powder matrix deposition. Depending on the matrix’s application amount, dry fiber can be either directly consolidated or preconsolidated for later impregnation with thermosetting resins. Our innovative setup enables the customised production of dry fiber using various fibers and thermoplastic matrices, with options for in situ functionalization. Furthermore, we are exploring the most efficient processes to produce composites from dry fiber, focusing on optimising the quantity, distribution, and compatibility of the matrix, ultimately enhancing the mechanical properties of the final product. This method is particularly advantageous for crafting complex, large-scale parts that endure significant mechanical stress.
Organosheets
Organosheets are pre-impregnated sheets of reinforcing fibres (woven or non-woven) with thermoplastic matrices, used in subsequent thermoforming or compression moulding processes to create complex geometries with good mechanical performance. AIMPLAS is developing organosheets with enhanced properties such as impact resistance, electrical conductivity, or improved fire performance. These materials are widely used in the automotive industry for manufacturing multifunctional, lightweight, durable, and more sustainable components.
These innovations in developing multifunctional thermoplastic composites have opened new opportunities across various industries. The ability to produce lightweight, durable, and multifunctional materials is crucial for developing more sustainable and efficient products. For this reason, AIMPLAS continues to research and develop new technologies to improve the properties of composites, reduce their cost, and expand their applications.
Equipment
- Microwave curing
- RTM, RTM-Light and infusion
- Pultrusion
- Polyurethane dosing and mixing
- Solid surface formulation
- Compression moulding pilot plant
Frequently Asked Questions about Composites
Composites combine two components: a polymer matrix and a reinforcement, usually made from glass, carbon or natural fibres. The matrix holds the fibres together and transfers the loads to them; the fibres provide strength and stiffness. The result is lightweight components with very good mechanical properties and high resistance to corrosion and degradation, which are used in sectors such as aerospace, construction, automotive, marine and sports.
The difference lies in the matrix. In thermoset composites, the resin (for example, epoxy or polyester) cures irreversibly: once the part has been manufactured, it cannot be melted again. In thermoplastic composites, the matrix softens when heated, so the parts can be reshaped or welded. They are generally manufactured using shorter cycles and are easier to recycle. AIMPLAS develops thermoplastic composites in formats such as UD-tapes, organosheets, short-fibre composite processes and LFTP.
The curing of thermoset resins can be optimised in two ways: by accelerating it and by controlling it. To accelerate curing, non-conventional curing technologies such as microwaves or UV radiation can be used and adapted to processes such as RTM, infusion or pultrusion. To control it, dielectric analysis (DEA) is used to monitor the evolution of curing inside the mould in real time and determine when the part is ready, without extending the cycle longer than necessary.
Yes, although this is more complex than recycling thermoplastics because the cured resin cannot be melted again. The main routes are:
- Mechanical: crushing the composite for use as a filler.
- Thermal: for example, pyrolysis to recover the fibres.
- Chemical: for example, solvolysis to separate the fibre from the resin.
AIMPLAS carries out recyclability and reuse studies on thermoset waste and develops processes to valorise end-of-life tyres and other thermoset materials.
Biocomposites are composite materials in which the reinforcement, the matrix or both are of natural or renewable origin, for example, flax or hemp fibres combined with bio-based resins. They can reduce the weight and environmental footprint of components. AIMPLAS adapts production processes to these materials and optimises their properties, for example, in interior panels for transport and construction.
We have cutting-edge machinery for developing projects
We provide customised assistance to solve processing problems
We offer specialised training on composite material processing
