Thermoplastics at Langzauner – Your Complete Solution for Fiber-Reinforced Components
From consolidation to the finished functional component – Langzauner offers everything from a single source for the efficient processing of fiber-reinforced thermoplastics.
With decades of experience in composites projects, we deliver one-stop-shop solutions for international clients who expect custom, turnkey solutions.
Many Processes. One Goal: Flawless Thermoplastic Components with No Compromises
The finishing and shaping of fiber-reinforced thermoplastics is complex, and many production lines remain fragmented: separate suppliers handle tape, consolidation, molding, and post-processing. Common consequences include a lack of process integration, interface losses, quality variation, and increased lead times.
Langzauner closes this gap with integrated solutions, optimized for:
- Precision & Efficiency
in industries with high demands on quality and fast throughput for thermoplastic component manufacturing.
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Our Solution: A Complete Thermoplastics Process Chain
| Process Stage | Benefit / Advantage |
|---|---|
| Consolidation | Void reduction, optimal fiber-matrix bonding, homogeneous preforms |
| Stampforming (Molding) | IR heating, fast forming, short cycle times, high geometrical precision |
| Hybrid Molding (Overmolding) | Integration of functional features directly in the press (bolt-on) |
| LFT-D (Long Fiber Thermoplastic – Direct) | Continuous fiber impregnation, high energy absorption, recyclability |
Fiber-reinforced plastics: high-performance materials for lightweight design
| Abbrev. | Full name (English) | Typical automotive applications (fiber-reinforced / matrix) | Typical aerospace applications (fiber-reinforced / matrix) |
|---|---|---|---|
| PP | Polypropylene | GF‑PP for front-end carriers, bumper beams, instrument panel carriers, fan shrouds, door modules, interior trim parts. | Mostly simple interior panels or secondary parts, rarely highly loaded structures. |
| PA6 / PA66 | Polyamide 6 / Polyamide 66 | GF/CF‑PA for structural modules (pedal brackets, front-end carriers), housings, coolant and air ducts. | Technical parts, clips, brackets and fasteners with higher temperature and media resistance. |
| PPS | Polyphenylene sulfide | High‑temperature engine compartment parts, pump housings, connectors, e‑mobility high‑voltage electronics. | Structural and system components with high temperature and chemical resistance. |
| PEEK | Polyether ether ketone | Highly loaded bearings, bushings, seals, performance/motorsport parts, electrical and electronic components. | CF/PEEK tapes and laminates for structural parts, clips, brackets, mounts, bearings and housings. |
| PAEK | Polyaryletherketone (family) | High‑performance parts similar to PEEK/PEKK, e.g. structural parts, gears, pumps, e‑powertrain components. | CF/PAEK tapes and organosheets for primary/secondary structures, clips, ribs, stringers, brackets. |
| PEKK | Polyether ketone ketone | High‑temperature and FST‑critical parts, especially in E&E and specialty vehicles, metal replacement. | CF/PEKK structures such as pylons, stringers, shells; interior and structural components with high FST. |
| LMPAEK | Low‑melt polyaryletherketone | Niche material where lower processing temperatures for complex CF tapes/organosheets are beneficial. | LM‑PAEK CF tapes for fast AFP/press forming of primary and secondary structural parts. |
| PEI | Polyetherimide | Connectors, E&E parts, heat‑resistant housings and brackets in the engine compartment. | Aircraft interior parts (seat structures, panels), ducts, electrical components with FST requirements. |
| PSU / PPSU | Polysulfone / Polyphenylsulfone | High‑temperature connectors, fluid components, pump and valve parts. | Lightweight parts with high temperature and impact resistance, e.g. covers, brackets, fluid and connector systems. |
As a custom machinery supplier, Langzauner provides all services to consolidate multiple process steps into a holistic solution:
- Engineering
- Press design & construction
- Automation
- Sensor technology & quality monitoring
With our one-stop approach, we appeal to international customers seeking a full-scope solution for complex thermoplastics processes.
Your Advantages with Langzauner as Your Partner
- Performance & Scalability: Presses up to 100,000 kN closing force
- Process Temperatures up to 500 °C: Precision zoned heating & cooling technology
- Bolt-On Injection Unit: Fully integrated into HMI
- Precision & Energy Efficiency: Servo-hydraulic drives
- Modular Automation: Handling, transfer, QC, stacking
- Digital Process Control: Data logging, traceability, recipe management
- Future-Proof & Flexible: Modular design, upgradability, expandability
- Service: Maintenance, spare-parts service, retrofit, process optimization
Technology & Process Modules in Detail
Langzauner brings together all relevant technologies to manufacture complex thermoplastic components in a comprehensive process:
Consolidation
- Batch: hot / cold pressing of tape stacks
- Aim: low porosity, defined crystallinity, reproducible properties
Forming (Stampforming)
- Preheating via IR, contact or convection
- Transfer into temperature-controlled tooling
- Cycle times < 60 s
- Applications: structural parts, crash elements, underbody covers
Hybrid Molding (Overmolding / Bolt-On)
- Press = closing module, laterally coupled injection unit
- Materials: ABS, PC, PA, PEEK, etc.
- Injection pressure > 1,900 bar, volumes > 1,600 cm³
LFT-D (Long Fiber Thermoplastic – Direct)
- Direct integration of long fibers > 10 mm
- Very high energy absorption, short cycle times
- Scalable from lab to high-volume production
Heating Methods for Thermoplastics
Depending on the application and process requirements, Langzauner offers different heating technologies:
| Heating Method | Principle | Advantages | Constraints | Typical Applications |
|---|---|---|---|---|
| Infrared (IR) | Radiation energy → absorption by the matrix | Very fast heating; non-contact; flexible, zone controllable | Possible uneven heating; surface overheating | Stampforming, Hybrid Molding (automotive) |
| Convection (Hot Air) | Hot airflow over material | Very uniform temperature; gentle for thick laminates | Slower heating; higher energy use | Preheating preforms, batch consolidation |
| Contact Heating | Direct contact with heated plates / jaws | Very efficient; homogeneous core; precise control | Surface impressions possible; limited to flatter geometries | Consolidation of tapes / laminates, heated jaws |
| Induction / Dielectric | Induction: eddy currents (for carbon) / Dielectric: molecular rotation (HF / microwave) | Very fast volumetric heating; locally controllable; suitable for in-situ | Material dependent; homogeneity challenging; high capital cost | AFP, aerospace specialty processes, rapid preheating of organosheets |
Each method has strengths and limitations — we choose the optimal solution with you, based on material, geometry, and production volume.
Typical Applications & Industries
- Automotive: front ends, battery housing, underbody covers, crash structures
- Aerospace: lightweight structural parts, components using welded vs riveted joints
- Industrial & Construction: pallets, machine housings, panels, formwork
- Specialty Segments: high-performance plastics, bespoke solutions
