Innovative Multi-Die, Vacuum-Assisted Pultrusion System for Thermoplastic Composites

Automobile and Aerospace, Materials, Science & engineering

UNMET NEED

The quest for scalable production of composite materials—ranging from rods and beams to intricate profiles like window frames—demands an advanced manufacturing solution. Pultrusion has traditionally been the method of choice. However, conventional pultrusion methods, reliant on thermoset resins and glass fibers, fall short due to their lack of recyclability, inability to be welded, and non-reusability. The escalating demand for safer, greener and more adaptable products today calls for a transition towards thermoplastic resins, enriched with a wide spectrum of reinforcing fiber yarns, to overcome these limitations. Existing pultrusion systems lag in delivering the needed quality standards, especially in terms of high reinforcement content, minimizing porosity, and securing unparallel surface finishes, all while maintaining high throughput and profitability.

TECHNOLOGY OVERVIEW

Our proprietary Multi-die Vacuum-Assisted Pultrusion System sets a new standard by meticulously blending reinforcing filaments with thermoplastic polymers. This patented technology seamlessly integrates heating, compression, vacuum degassing, and cooling across multiple dies, accurately engineering the transformation of hybrid yarn precursors into superior composite beams. Featuring an exclusive cooling technique, our system achieves unparalleled surface finishes. Moreover, the system guarantees thorough impregnation of reinforcement fibers, delivering high-quality, high-yield production ready to meet the demands of a wide range of industrial applications.

We have successfully demonstrated and optimized our technology across a broad spectrum of thermoplastic resins and fiber yarns, both synthetic and natural, as well as various geometries, providing exceptional versatility for demanding applications.

 

COMPETITIVE ADVANTAGES

  • Exceptionally low void content (<1%)
  • Premium surface finishing (Ra < 0.6 µm)
  • Compatibility with a broad spectrum of thermoplastic resins: PET, PP, PLA, Nylon (PA6, PA66), PPS, PEI, PEEK

 

BUSINESS OPPORTUNITY

  • Partnering and licensing across commercial sectors
  • Accessing funding for industry-university technological maturation programs

 

MARKET APPLICATIONS

Our technology is primed for a broad range of applications, having been tested in fields of sporting goods, transportation, aerospace, and construction.

 

IP PROTECTION

  • Patents granted in Canada, USA and Europe.

CONTACTS

Louis Laberge Lebel

PRINCIPAL INVESTIGATOR
Associate Professor, Mechanical EngineeringEngineering
Polytechnique Montréal

Andréa Arias

CONTACT PERSON
Project Director, Business Development
Axelys
andrea.arias@axelys.ca