Your thermoplastic pultrusion partner

Thermoplastic pultrusion combines continuous fibers with the benefits of thermoplastics in a single profile for optimal mechanical properties at a low weight. We develop pultrusion processes with different fiber 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 process.
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Melt pultrusion

Ensinger has specialized 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.

Continuous fibers

Using continuous fibers to optimize mechanical properties.

  • Glas fibers
  • Carbon fibers
  • Aramid fibers
  • Custom solutions

High strength, low weight

Optimal mechanical properties at a low weight.

  • High breaking strength
  • High impact strength
  • High stiffness
  • Up to - 60 % weight savings

Beneficial materials

Beneficial properties of thermoplastic materials:

  • Recyclable
  • Weldable
  • Thermoformable
  • Overmouldable

continuous fiber-reinforced profiles for an optimized CO2 Footprint

Continuous fiber reinforced profiles offer great benefits in terms of resource efficient material use: It can replace metal and thermoset materials, reducing the carbon footprint. It can be reused by melting and, if necessary, shredding, providing an opportunity for material recycling. Both the material and the thermoplastic profile can be recycled.

Reduce your CO2 footprint with continuous fiber reinforced profiles manufactured with thermoplastic pultrusion:

  • Recyclable materials and profiles
  • High strength and durability even in extreme conditions
  • Significantly lighter than metal (up to -60% weight saving)

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

The targeted, application-related fiber placement of the rovings enables optimum, punctual load absorption. The bundled continuous fibers are placed at defined points to optimize the load-bearing capacity in the longitudinal direction and other mechanical properties of the profile. Short fibers can also be added to support the absorption of transverse loads.
Melt-pultruded profiles are resilient even under extreme conditions, durable and characterized 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 fiber (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 fibers

 1,7 240  15.500
Pultruded profile made of PA with 47 vol% glass fiber (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 fibers 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 optimized 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, customized geometries can also be produced using melt pultrusion.

Thermoplastic Pultrusion Technologies

Fibre-reinforced plastic profiles are manufactured in a continuous process. The bundled glass and carbon fiber rovings help to optimize the tensile and bending strength. The rovings are precisely positioned for optimized load-bearing and bonded to the thermoplastic during the production process. During impregnation, the fiber rovings are completely impregnated and form a firmly bonded profile with the material for maximum stability. 
 
Thermoplastic profiles reinforced with continuous glass fibers have a high strength similar to that of aluminum profiles while at the same time reducing weight.
Depending on the selected plastic, fiber content and arrangement of the rovings, individual profiles with different properties can be pultruded. The very high fiber content in combination with unidirectional alignment and local fiber 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 fibers and offer customized solutions

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