Discover the Hybrid Injection Process of Polymer on CFRP Plate
Development of a Self-Reinforced Structure in Thermoplastic Composite
In a world striving for sustainable innovations, design flexibility, and cost reduction, composite materials emerge as the architects of transformation. They offer an unparalleled combination of lightness, strength, and versatility, revolutionizing the way we design and build the future.
Hybrid Injection
Leveraging years of expertise in thermoplastic injection technology and the integration and qualification of a dedicated CFRP (Carbon Fiber Reinforced Polymer) stamping line for the aerospace market, Clayens NP is developing a "hybrid" process that combines both technologies.
This new process allows for the creation of a thermoplastic part in a single step, meeting a very precise set of specifications in terms of geometric complexity, dimensional accuracy, mechanical stresses, and more. It combines the advantages of both technologies, such as the ability to use the mechanical performance of continuous fiber only in the areas of the part that require it, and the creation of a complex-shaped part with varying thicknesses or the addition of ribs.
This process overcomes the major drawbacks of each technology, such as eliminating the machining trimming step in stamping, thereby reducing production costs and optimizing raw material usage.
Adaptability to All Industries
Whether you are in aerospace, automotive, energy, healthcare, or other sectors, this hybrid technology adapts to all industries. It offers a versatile solution for various applications, marking a significant step towards the widespread use of reinforced composites.
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The overmolding process allows stamping and direct injection in a single mold in one step to produce a finished part ("net shape").
But how does it actually work?
The overmolding process can be broken down as follows:
- The thermoplastic composite blank reinforced with continuous fibers is heated using a heat source, preferably an infrared oven.
- The "softened" blank is introduced into the injection mold via a gripping system.
- Upon closing the mold and stamping the CFRP, thermoplastic granules reinforced with short fibers are injected into predefined areas by cavities in the mold.
- As with the standard injection process, the mold remains closed for the plastic material to cool and set.
- The part is then ejected from the injection mold, consisting of a mechanically highly efficient "skeleton" or "frame," along with the edges of the parts, ribs, and thickened areas made of injected thermoplastic.
Hybride process
The primary polymer matrices used in this process (standard aerospace applications) include polymers and copolymers from the polyaryl ether ketone (PAEK) family such as PEEK or PEKK, polyphenylene sulfide (PPS), polyetherimide (PEI), and polyamides (PA).
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How Clayens NP Can Help / Our Added Value ?
Our goal is to support you in technical development. We bring our expertise in this technology by optimizing process parameters (to achieve maximum mechanical performance at the interfaces), testing different matrices that may meet your specifications: mechanical, chemical, thermal, etc.
Additionally, we can perform numerical simulations of this process (rheology) and mechanical simulations (interface modeling, stress simulations experienced by the parts in their environment, and assessments of their performance and resistance).
Feel free to check out our research project : ARCHES 4.2 in collaboration with STELIA : https://www.clayens.com/actualites/le-projet-de-recherche-arches-42.
Clayens NP’s objectives are to propose innovative concepts and verify their mechanical characteristics, rigidity, and applicability in your field of activity.
Don't hesitate, contact us for more information !
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Camille BRAMAS
R&D Project Manager
Mob : +33 6 82 39 20 96
Mail : camille.bramas@clayens.com