As reported by Composites World
Extending FibreCoat GmbH’s (Aachen, Germany) patented coating platform from metals to polymers, PolyCoat integrates thermoplastics directly at the filament level, enabling easier processing, faster impregnation and more consistent composite quality for thermoplastic composites (TPC) manufacturing.
According to the company, making TPC at scale is slow because it is hard to spread the polymer evenly between all of the fibers without trapping air — a production bottleneck. FibreCoat’s PolyCoat, however, coats glass filaments individually with polymer during fiber spinning, when the fibers are already separated. This avoids air gaps, simplifies downstream processing and results in faster production and stronger materials.
“For years, manufacturers have had to choose between good material quality and fast production,” says Dr. Robert Brüll, CEO of FibreCoat. “PolyCoat delivers both by getting the plastic exactly where it is needed, without slowing the process down, which opens the door to reliable production — in high volumes — of lighter, stronger and more sustainable composite parts.”
PolyCoat is designed for short and long glass fiber-reinforced plastics, noncrimp fabrics, unidirectional tapes and molded parts. It works in a similar manner to FibreCoat’s aluminum coating process for producing its flagship product, AluCoat, but uses a thermoplastic matrix instead of metal. With PolyCoat, FibreCoat’s goal is making the product at scale, testing it and producing samples for customers on a new in-house, large-scale glass fiber spinning line that also allows for customer trial and development.
Sustainability is also a core goal, Brüll adds. By removing processing steps and speeding up production, the process reduces energy use and cost, and makes lighter parts that last longer.