Thermoplastic organosheets

Recyclable, easily thermoformable, stiff, strong and light: Thermoplastic organosheets set new standards and offer a wide range of applications in numerous industries. Organosheets are high-performance, continuous fibre-reinforced composites made of carbon or glass fibre fabric embedded in a thermoplastic matrix. The excellent mechanical properties at low density allow weight savings of up to 60% compared to metals.

The multilayer, fully impregnated and consolidated organosheets are manufactured at Ensinger on a double belt press from prepreg or semipeg material, whereby the components used can be individually adapted to the application. 

Organosheet composite portfolio

Organosheets basically consist of several layers of thermoplastic prepreg or semipreg material which are stacked and then pressed into a sheet with a thickness of up to 5 mm. On request, the organosheets can also be produced according to individual specifications regarding fibre orientation or layer thickness.

All our prepreg and semipreg materials can be further processed into organosheets. Thanks to Ensinger's own compounding, we can offer special blends and compounds in addition to the standard materials and adapt all matrix and fibre combinations as well as fibre architectures individually to your application. The choice of matrix material is diverse: the matrix materials can range from technical polymers such as polyamides to high-performance plastics such as PEI, PEEK and PEKK. High-quality materials such as polycarbonate and SAN are also available for visual applications.

The organosheets are supplied as standard in sheets 1,20 m wide. The length of the sheets can be individually defined depending on the application. For some materials, widths of up to 1,70 m are possible.

further processing of Organosheets

Organosheets are suitable for numerous applications due to their beneficial properties. Due to the recyclability of the materials used, organosheets can meet new requirements for sustainable designs. 
In fast processes such as thermoforming and overmoulding, organosheets can be used to produce cost-effective components in large quantities, also in high visual quality.
In thermoforming, an organosheet is heated by radiant heaters to above the melting point of the polymer and formed into the part by special moulds. Thermoforming offers several advantages:

  • Fast cycle times: thermoforming takes only a few seconds to a few minutes,
  • Possibility for automation, which ensures consistent quality,
  • Recyclability of the material and scrap and thus the avoidance of large amounts of waste,
  • Direct forming into the final component through a single-stage process.

Thermoforming can be used for organosheets with a thickness of up to 5 mm.

Organosheets can also be further processed in the overmoulding process. In this process, the thermoplastic composite laminate is first thermoformed and then overmoulded in an injection moulding process. Overmoulding is particularly suitable for the production of parts with complex structures and allows for:

  • Outstanding structural rigidity with low weight
  • A high degree of functional integration
  • Easy automation and use for high-volume production

Applications and Industries

Organosheets can be used for all thermoformed parts or for the simple production of thicker parts. The areas of application are diverse - thanks to their advantageous mechanical, thermal and chemical properties, organosheets made of thermoplastic composites can revolutionise numerous applications and create completely new approaches and opportunities in various industries. Ensinger covers the entire value chain and is therefore a transparent, reliable and competent partner.