Polyamide UD Tapes Contribute to Vehicle Lightweighting

The High-Performance-Thermoplastics (HighPerTherm) project, a joint effort of the Fraunhofer Institute for Microstructure of Materials and Systems (IMWS) and materials supplier Domo Engineering Plastics, has developed novel glass-fiber polyamide (PA) tapes for use in innovative and cost-efficient lightweight structures for large-scale production. The aim is to expand the range of applications for semi-finished products made of continuous fiber-reinforced thermoplastic tapes for efficient use in structures that come under high stress.

As part of the project, Fraunhofer IMWS dedicated itself to the optimization and further development of process technology for the production of continuous fiber-reinforced thermoplastic semi-finished products as well as their characterization. The matrix system developed by Domo Engineering Plastics as well as extensive analyses and optimization of process parameters led to a significant increase in the mechanical performance of the semi-finished tape products compared with conventional materials. Furthermore, a significant improvement of processability was achieved with the newly developed matrix systems, enabling a significant increase of fiber wetability in the semi-finished product as well as an improvement of the process’s long-term stability.

"Through targeted material- and process-specific development steps, we have achieved increases in the fiber volume fraction in the tape semi-finished products and determined optimal parameters that enable the production of unidirectional (UD) semi-finished products with optimized mechanical performance," said Benjamin Tillner, subproject manager for semi-finished product development.

Domo Engineering Plastics is a manufacturer of PA 6 and 66 based in Ghent, Belgium. Domo has been marketing the UD tapes under the commercial name Technyl Lite since 2022.

Fiber-reinforced plastics, which can replace metallic materials and structures, play an essential role in reducing CO₂ emissions. By means of lightweight construction, raw materials, costs, and energy can be saved in the manufacture as well as in the use and recycling of a product.

Consisting of continuous reinforcing fibers and a plastic matrix, UD fiber composite tapes have better mechanical properties than conventional particle or fiber-composite plastics. Due to their versatility, they can be used in mechanical engineering applications and in various sectors, including automotive, aerospace, and building and construction.

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Image courtesy of Fraunhofer IMWS.