Cost-efficient carbon fibre inserts for injection moulded parts are considered by many to be the Holy Grail for plastic components. A new technology has now achieved the long-awaited breakthrough.
Injection moulded parts are characterised above all by their low production costs and high quantities. However, depending on the plastic used, they quickly reach their load limits. Fibre-reinforced plastics made of carbon or glass fibre, as are often used in the aviation industry, offer an alternative. Although these materials increase performance considerably, the complex manufacturing process, which differs significantly from injection moulding, leads to high costs.
For this reason, inserts made of different fibres have been used in injection moulded parts for many years. One possibility is the use of homogeneous sheets, so-called organo sheets, which are first moulded into the desired shape. Here too, the costs are considerable due to the high fibre content. More efficient are inserts made of organically shaped fibres, as shown in the picture. These fibre structures take on the loads, although the fibre content remains low. However, current manufacturing processes such as 3D printing or embroidery techniques are not suitable for large-scale production.
A new process developed by fibionic.at combines the rapid production of inserts from organic sheets with the advantages of organic fibre structures. This technology enables the production of inserts in just a few seconds and thus cost-effectively raises injection moulded parts to the performance level of typical fibre composite components.
A series machine developed by micado.at enables fully automated production of inlets of up to 400mm x 400mm every minute.
The first companies from the sporting goods industry will start series production as early as 2025.
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