Composite engineering

Composite engineering and manufacturing

The creation of each composite part undergoes a process that consists of several steps, as follows: 

1. Design and engineering

Ensinger offers extensive design and engineering capabilities. Customers profit from Ensinger’s expertise in developing composite parts using tailored design, materials and processes. Together with the customer, our engineers optimize the part for composite manufacturing and adapt the materials and processes to the customer’s specifications.

Composite design

2. Material selection

With more than 50 years of experience in high performance engineering plastics, Ensinger helps you choose the right combination of polymer and fibres for each application. The composite matrix material portfolio ranges from standard and engineering plastics to high performance polymers, including both semi-crystalline and amorphous products. Reinforcement fibres can be chosen from most available fibre materials and grades.
Composite materials fibres and prepregs

3. processing technologies

In close collaboration with the customer, Ensinger applies its processing technologies for thermoplastic composites to suit each specific part. If required new manufacturing processes are developed. 
Composite manufacturing

4. Prototyping

Parts prototypes for testing purposes are manufactured by Ensinger using near-series tools, machines and processes. Whether it be a few parts demonstrating the feasibility or a small series made out of a production mould, Ensinger has the capability to satisfy the customer‘s requirements.
Composite prototyping

5. Manufacturing

After successful development, serial production will take place at an Ensinger production facility. 
Ensinger has developed a broad range of composite manufacturing processes to fulfil the customer requirements such as 3-dimensional parts, short cycle times or automation. Our core processes allow us to achieve economic advantages for small and high volume series. 
Cmposite manufacturing, pressing machine

examples of processing technologies

example for net shape thermoplastic composite

Net shape process

Our core technology allows us to manufacture 3-dimensional parts with increased geometrical complexity, variable wall thickness and inserts.

Round pressing process

A unique press know-how allows the manufacturing of round parts up to cylindrical parts with variable wall thickness. 

example for foam filled thermoplastic composite

Hollow pressing process

Lightweight structures such as hollow profiles or 3-dimensional parts can be produced with lost or removable cores. Even structures with vertical walls are possible with a dedicated technology.

Medical grade plastic PEEK composite material TECATEC PEEK CW

Plate pressing

Composite shapes such as TECATEC can be manufactured up to a thickness of 140 mm.

Different surfaces of thermoplastic composites

Surface modification

Composite parts and stock shapes can be coated with functional surfaces, for example FEP to optimize dynamic friction or metal to increase hardness and wear resistance.

damast surface composite

Damask appearance

Thermoplastic composite damask has an unique appearance. The damask structure can be manufactured as stock shape or sliced into a thin veneer. It can be used for jewelry or luxury interiors.