Processing Solution
The Xplore Tow Impregnation Line is a compact laboratory-scale system for the rapid development and screening of continuous fibre-reinforced thermoplastic filaments, using only minimal amounts of material.
Fully integrated with Xplore Micro-Compounders, it lets researchers formulate new polymer compounds and convert them directly into impregnated continuous fibre filaments, ready for evaluation.
- One integrated workflow: material formulation and precision melt impregnation in a single system, with no material transfer between steps.
- Minimal material use: screen new formulations from minimal material quantities, cutting development time and cost.
- A clear path to scale-up: validate composite feedstock performance before committing to industrial production.
Capabilities
- Fibre Compatibility: Process carbon, glass, aramid, basalt, UHMWPE, natural, and metallic fibres.
- Material Compatibility: Process PP, PA, PC, PET, TPU, PEEK, PEI, PPS, and other thermoplastics.
- Composite Filament Production: Produce continuous fibre-reinforced thermoplastic filaments for additive manufacturing and evaluation.
- Process Optimization: Optimize fibre spreading, impregnation, consolidation, and composite performance.
Key Features
- Controlled Fibre Handling: Tension-controlled unwinding and guiding.
- Precision Impregnation: Interchangeable die dimensions and in-melt fibre spreading.
- Adjustable Processing: Tunable line speed and haul-off control.
- Controlled Winding: Torque-controlled take-up winding.
- Process Monitoring: Real-time process visualization and monitoring.
Research Areas
- Fibre-Reinforced Filaments: Continuous fibre composites with engineering and high-performance thermoplastics.
- Fibre–Matrix Studies: Fibre spreading, impregnation, and interface optimization.
- Lightweight & Sustainable Composites: High-performance and sustainable composite systems.
- Composite Quality: Fibre volume fraction, void content, and uniformity.
- Process & Scale-Up: Process optimization, material validation, and scale-up.
Applications
- Composite Additive Manufacturing: CFAM and 3D composite printing.
- Lightweight Structures: Automotive, aerospace, UAV, and robotic applications.
- Pressure & Containment: Pressure vessels, pipes, and containment structures.
- Medical & Wearable Composites: Prosthetics, orthotics, and wearable devices.
- Advanced Composite Design: Fibre-path, consolidation, and load-oriented structure development.
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