Your thermoplastic pultrusion partner

Thermoplastic pultrusion combines continuous fibres with the benefits of thermoplastics in a single profile for optimal mechanical properties at a low weight. We pultrude profiles with different fibre contents, thermoplastic materials and geometries to meet the requirements of each individual application.
With our in-house compounding facility and highly skilled thermoplastic pultrusion development experts, we offer end-to-end support throughout the development process.
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Melt pultrusion

Ensinger has specialised in the melt pultrusion process. Compared to thermoset pultrusion, thermoplastic pultrusion scores highly in many respects. The technology developed by Ensinger has the following three main advantages.

Sustainable - in processing and recycling

Compared to thermosets, thermoplastics are the more environmentally friendly solution. They are

  • recyclable 
  • low in pollutants during further processing, e.g. sawing and milling

Mechanically resilient - thanks to targeted fibre reinforcement

The targeted arrangement of bundled continuous fibres (rovings) combined with short fibres contributes to 

  • optimised absorption of the transverse and longitudinal load  
  • optimised mechanical properties (break-resistant, impact-resistant and rigid)
  • considerable weight savings of approx. 40-50%

Versatile - in material, properties and geometry

Depending on the application and function, materials, fibres and additives are selected for

  • an optimum property profile 
  • customised dimensions and geometries

continuous fibre-reinforced profiles for an optimised CO2 Footprint

In view of increasingly stringent environmental regulations, thermoplastics are gaining in importance as a more environmentally friendly solution compared to thermosets and metals such as aluminium. Thermoplastics replace metal and thermoset materials and thus reduce the CO2 footprint. Thermoplastic materials can be reused by melting them down and shredding them if necessary, thus offering an opportunity for material recycling. Thermoplastic profiles are also characterised by low-pollutant processing. For example, they can be sawn and milled with low emissions.
 

Further processing and functional glazing
Thermoplastic pultruded profiles can be ideally combined with other thermoplastic components and processes. This allows complex components with a high degree of functionalisation to be realised. For example, the profiles can be welded together with thermoplastic composite materials as structural elements or used as reinforcing elements in the overmoulding process.

 

Targeted and weight-saving load support with TFP (Tailored Fibre Placement)

The targeted, application-related fibre placement of the rovings enables optimum, punctual load absorption. The bundled continuous fibres are placed at defined points to optimise the load-bearing capacity in the longitudinal direction and other mechanical properties of the profile. Short fibres can also be added to support the absorption of transverse loads.
Melt-pultruded profiles are resilient even under extreme conditions, durable and characterised by impact resistance, rigidity and breaking strength. Compared to metals, up to 50 % weight can also be saved.

Material

Density  

Flexural strength  

Modulus of elasticity  
   [g/cm2]  [MPa]  [GPa]

Auminium EN AW-6060 T66

 2,7 215  69.500

Pultruded profile made of polyester resin
with 40 vol% glass fibre (UD) rovings

 1,8 250  28.000
 
   

Extruded profile made of unreinforced PA

 1,1 100  2.900

Extruded profile made of PA with 40 vol% short glass fibres

 1,7 240  15.500
Pultruded profile made of PA with 47 vol% glass fibre (UD) rovings 1,8 400  37.500

Customised profiles with great design freedom 

Our extensive portfolio of high-performance and engineering plastics, in combination with continuous and short fibres and other additives, offers the right material matrix for a wide range of applications. Based on the individual application and requirements, our experts select the suitable material and additives. A wide range of optimised mechanical, electrical, chemical and tribological properties can be achieved. For example, corrosion protection, electrical insulation, flame retardancy and surface smoothness open up a wide range of applications. Complex, customised geometries can also be produced using melt pultrusion.
 

 Thermoplastic Melt Pultrusion Technology

Fibre-reinforced plastic profiles are manufactured in a continuous process. The bundled glass and carbon fibre rovings help to optimise the tensile and bending strength. The rovings are precisely positioned for optimised load-bearing and bonded to the thermoplastic during the production process. During impregnation, the fibre rovings are completely impregnated and form a firmly bonded profile with the material for maximum stability. 
 
Thermoplastic profiles reinforced with continuous glass fibres have a high strength similar to that of aluminium profiles while at the same time reducing weight.
Depending on the selected plastic, fibre content and arrangement of the rovings, individual profiles with different properties can be pultruded. The very high fibre content in combination with unidirectional alignment and local fibre reinforcement enable complex geometries. 
There are no limits to the choice of matrix material: As plastics experts, we can advise you on the selection of the right plastic in combination with continuous fibres and offer customised solutions
 

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