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Plastics Discovery Tour

Fakuma

Circular economy with CFRP: strategies for recycling carbon fiber waste as holistically as possible.

Examples of various carbon fiber materials, including fabric, short fibers and recycled carbon fiber-reinforced plastic (rCFRP) compounds.

16:9

Recycling

Verbundwerkstoffe / Werkstoffverbunde

Faserverbundwerkstoffe

Kunststoff-Recycling

Kreislaufwirtschaft

How the Circular Economy Works with Carbon Fibers

“Paper Pearls” material opens up the possibility of integrating plastic-free, highly filled paper fiber blends into applications previously reserved for plastics – using standard injection molding machines and processes.

The “Slot-Lock” positioning tools, which are injection molded from “Paper Pearls” (here with 51 % fiber content) and weigh around 20 g, are sustainable, stable and compostable after use.

Spritzgießen

Doriat, Clemens, Dr.

Faserverarbeitung

Nachhaltigkeit

Injection Molded Parts for the Paper Bin

Wood can also be used as a basis for plastics and can be processed into reinforcing fibers. But are these fibers also suitable for technical components?

The reinforcing effect of the fibers was investigated on wood fiber nonwovens, among other things.

Fasern

Kunststoff Werkstoffe

Holz

Renewable Reinforcement Fibers

Fakuma: The European IM machine manufacturers are working on solutions for the future – apparently under increasing competitive pressure from the Far East.

Yizumi used a 6-station mold to produce thick-walled optical lenses from PMMA. Engel had introduced this type of multilayer injection molding over ten years ago.

Schaumspritzgießen

Temperiertechnik

Mehrkomponenten-Spritzgießen

Folientechnik (IMD, IML, FIM, u.a.)

Spritzgießwerkzeuge

Messe Fakuma

Spritzgussteile, allgemein

Handling, Handhabungstechnik

Headwind from the East

With the duo 5500 combi M technology center machine, Engel offers the opportunity to implement a variety of injection molding technologies for large components.

32 m long, 13  m wide, 6.8 m high and weighing 545 t: The large Engel duo 5500 combi M machine with a clamping force of 55,000 kN has recently been installed at the Technology Center in St. Valentin, Austria, for customer trials.

Composite-Halbzeuge

Elektromobilität

Spritzprägen

Oberflächentechnik

Industrie 4.0 für die Kunststoffverarbeitung

Spritzgießmaschinen

Injection Molding Technologies  on a Mega Scale

Thermoplastic sandwich molding enables automated production of 3D-molded components in lightweight sandwich construction and functionalization in the same mold.

Making interior components in the truck cab recyclable – with thermoplastic sandwich structures for storage compartments, for example. 

Fraunhofer IMWS: Processing thermoplastic fiber composite sandwich semi-finished products into interior components

Leichtbau

Reaction Injection Molding

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Sandwich Lightweight Structures in the Injection Molding Cycle

Renowned NIAR Institute relies on FiberForm technology from KraussMaffei.

Significantly lighter and more cost-efficient to process than metal: The thermoplastic window plates produced with FiberForm.

NIAR Institute of the USA and KraussMaffei: Conversion of passenger aircraft with FiberForm technology from KraussMaffei

From Passenger to Cargo Aircraft

Artificial intelligence methods and digital material characterization are revolutionizing process simulation for composite materials.

Particularly in the field of material and process development, there is an increasing shift of experimental work into the virtual space. The combination of conventional numerical methods with machine learning techniques offers great potential. Click for full view.

Simulation Produkt- / Formteildesign

Prozesssimulation

Machine Learning

Analysetools, FEM

Digitalisierung

KI (Künstliche Intelligenz)

From Fiber to Component – the Vision of Digitized Process Development

IKV Aachen and SK Industriemodell GmbH investigated how insulating mold coatings can be used to produce lightweight FIM molded parts with high surface quality.

With the CeraShibo mold coating, good surfaces with a high degree of structural freedom can be achieved (here with wood, cube and brush structure as an example).

Werkzeugbeschichten

Increasing the Quality of Visible Parts

Three processes for the functionalization of thermoplastic profiles.

In-situ pultrusion (left) is used to produce profiles (top right), which are then functionalized (bottom right). 

FRP profiles / lightweight construction / e-mobility for special vehicles with small series

Kunststoff-Profile

Automotive

Fügen / Verbinden

Modular Battery Kit for a Fire Engine

Illig is presenting sustainable packaging solutions made of dry natural fibers (dry fiber) for the first time . The nonwoven material can be produced and processed with significantly lower energy and without the use of water.

Fiber-based packaging with a high drawing ratio – such as round cups and trays – can be produced economically and sustainably using Illig‘s patent-pending process.

Verpackungsmaterial

Verpackungsanlagen

Verpackungsmaschinen

Illig Presents Dry Fiber Technology

Sabic and The Lubrizol Corporation have developed compatible material solutions well suited for various applications in the consumer electronics and mobility industries.

Potential applications for these complementary materials include laptops, cell phone cases and other electronics devices where durability, drop protection and a non-slip surface are needed.

Elektronik

Thermoplaste

Soft-rigid Material Solutions for Consumer Electronics

Thermoplastics from Lehvoss prove maximum resilience in e-bike frames during Xtreme Tech expedition in North Africa.

Endurance test for thermoplastics: The Moroccan desert is not only popular among bicycle fans, it is also an excellent testing ground for plastics. 

Polyamide

Mobilität

Endurance Test in Front of a  Spectacular Landscape

New simulation method for the production of fiber-reinforced plastics: why the IKT relies on phased array ultrasound technology (PAUT).

Messtechnik

Resin Transfer Molding

Ultraschallprüfgeräte

To Know What Happens in High-Pressure Resin Transfer Molding Tools

Teaching materials manufacturer Wissner relies on renewable raw materials, processing is possible with standard plasticization.

Driving forward the development of sustainable teaching and play materials together (from left): Jörn Wissner, Simon Hagemann, Jess Wissner, Jürgen Wissner (all Wissner GmbH) and Peter Meisel, Regional Sales Manager KraussMaffei.

Kunststoff-Rezyklat

Wood Powder Only with  Standard Screw

FRPs are more difficult to recycle than unreinforced polymers. This changes when they are reinforced with polymer fibers instead of conventional fibers.

A major advantage of self-reinforced plastics is that they can be used in the morphology best suited to the application.

Additive

Lightweight Design with  Just One Material

Chopped fiber processing allows the direct processing of chopped glass fibers and significantly expands the field of application for long fiber-reinforced PP.

Processing of chopped glass fibers on a standard injection molding machine.

Schnecken und Plastifiziersysteme

Processing Chopped Glass Directly in the Injection Molding Process

Combination of 3D-printed polymer structures and near-net-shape organic sheets for complex, high-performance mono-material components.

Examples of 3D-printed lightweight components with and without NNS structures.

Combination of 3D-printed polymer structures and near-net-shape organic sheets for complex high-performance components.

Verfahren für die additive Fertigung

Additive Fertigung

Only the Component Is Complex

The life cycle assessment of FRP metal components is often moderate. This can be improved by using bioplastics and natural fibers.

As a demonstrator for the bio-hybrid components, a composite beam with an integrated metal insert with an omega profile (left) was manufactured. This was connected to the bio-FRP and a rib structure made from the bio-injection molding compound was molded on (right).

Biokunststoffe

 Sustainable Lightweight Design  with Bio-Hybrids

Zünd presented itself at JEC World 2024 as a leading one-stop solution provider for digital cutting in the composites industry.

Zünd focused on intelligent production processes and the requirements of Industry 4.0 at JEC World 2024 in Paris. 

Anlagen zur Composite-Herstellung

Solutions for Digital Cutting in the Composites Industry

The European composites market 2023 – AVK presents developments, trends, challenges and outlook

AVK presents current developments and trends for the European composites market.