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 specialises in the melt pultrusion process. Compared with thermoset pultrusion, thermoplastic pultrusion can offer application-specific advantages, including:

Mechanical resistance - thanks to targeted fibre reinforcement

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

  • optimized absorption of the transverse and longitudinal load  
  • high fracture strength, impact resistance, and stiffness

Versatility - in material, properties and geometry

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

  • an optimum property profile 
  • customized dimensions and geometries
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Continuous fiber-reinforced profiles for demanding applications

For certain applications, thermoplastic materials can be reprocessed by heating. This means they can, in principle, be reused or recycled into new materials, provided that suitable take-back and processing systems are available. 

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 functionalization 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 overmolding process.

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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