Processing Solution
The Xplore UD Tape Line is a compact laboratory-scale system for the rapid development and screening of high-performance thermoplastic unidirectional (UD) tapes, using minimal quantities of material.
Fully integrated with Xplore Micro-Compounders, it lets researchers formulate new polymer compounds and convert them directly into continuous UD tapes, ready for characterization and process evaluation.
- One integrated workflow: material formulation and continuous tape production 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: characterize and optimize UD tapes before committing to industrial production
Capabilities
- Material Compatibility: Process carbon, glass, aramid, basalt, UHMWPE, natural, and metallic fibres with commodity, engineering, bio-based, and high-performance thermoplastics.
- UD Tape Production: Produce tapes for characterization, overmoulding, automated tape placement, and scale-up.
- Controlled Impregnation: Achieve consistent fibre wet-out, low void content and optimized spreading.
- Process Optimization: Adjust tape dimensions, fibre volume fraction, and tape quality.
Key Features
- Compact & Modular: Benchtop UD tape system designed for laboratory-scale material development.
- Controlled Fibre Handling: Tension-controlled unwinding, configurable fibre spreading.
- Precision Impregnation: Temperature-controlled, hardened tool-steel die.
- Adjustable Processing & Collection: Tunable line speed, haul-off control, and torque-controlled winding for stable tape production.
- Process Monitoring: Intuitive software for real-time monitoring, with optional pressure transducer.
Research Areas
- Material Development: Advanced thermoplastic matrices and hybrid or functional UD tapes.
- Fibre–Matrix Optimization: Fibre spreading, impregnation, adhesion, and interface development.
- Sustainable Composites: Bio-based, natural-fibre, recycled, and recyclable composite systems.
- Tape Processing: Tape-quality optimization and feedstock development for ATL and AFP.
- Downstream & Scale-Up Studies: Overmoulding, thermoforming, joining, welding, mechanical performance, and scale-up.
Applications
- Transport & Aerospace: Lightweight structures for automotive, aerospace, rail, marine, UAV, and drone applications.
- Energy & Pressure Systems: Hydrogen vessels, tanks, pipes, EV battery structures, and renewable-energy components.
- Industrial & Infrastructure: Robotics, automated equipment, industrial machinery, and structural reinforcement.
- Hybrid Structures: Overmoulded components, thermoplastic sandwich panels, and hybrid parts.
- Medical & Consumer Products: Medical devices, prosthetics, orthotics, sporting goods, and high-performance products.
- Recyclable Structures: Recyclable thermoplastic composite components.
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