Efficient thermoplastic process for low-cost composite lightweight production

ENGEL, an Austrian-based injection moulding machine manufacturer, will showcase its new composite production technology at the JEC World 2023 event in Paris. ENGEL's organomelt process uses thermoplastic fibre composite preforms, formed and functionalised in one integrated step for high efficiency and full automation. The process also allows for a circular economy, enabling easy recycling of parts. ENGEL will demonstrate the potential of organomelt lightweight technology with a live machine exhibit producing inspection flaps for aircraft fuselages. ENGEL expects the organomelt process to see widespread use in both the aerospace and automotive sectors.

ENGEL has developed the organomelt process for efficient, large-scale production. It is widely used in the automotive industry and attracts interest from other sectors, particularly aerospace, which is increasingly moving towards thermoplastics. ENGEL's technology can produce purely thermoplastic parts and contributes to the aviation industry's goal of reducing CO2 emissions. The organomelt process requires fewer production steps, reducing assembly overheads and labour costs.

The organomelt process is particularly beneficial for producing inspection flaps for aircraft fuselages, which were previously produced as thermoset sandwich parts with milled aluminium parts bolted on. Using ENGEL's technology produces purely thermoplastic parts, which can be easily recycled. The aviation industry is particularly interested in lightweight construction technologies that reduce CO2 emissions, particularly for urban air mobility and logistics.

ENGEL's production of inspection flaps at JEC World 2023 in cooperation with customer FACC, alongside other project partners including Ensinger, Victrex, Kuraray, and Neue Materialien Fürth, showcases the many benefits of the organomelt process. Another partner company, Voidsy, will exhibit an ultra-compact system for using active thermography for zero-contact and non-destructive material and component testing.

ENGEL's focus on the organomelt process demonstrates the potential for large-scale composite production with high efficiency, low costs, and sustainability. Its live machine exhibit at JEC World 2023 will demonstrate its benefits for the aerospace and automotive industries, particularly for producing parts that are easy to recycle and reduce CO2 emissions.