The high-performance molding process of CFRT thermoplastic laminates is in line with the trend of Industry 4.0-Chengzi Tainuo (Shandong) New material Technology Co., LTD

The high-performance molding process of CFRT thermoplastic laminates is in line with the trend of Industry 4.0

Release time:

2025-08-27

Author:

Source:

In modern manufacturing, the integration of high-performance materials and advanced manufacturing processes has become a core source of competitiveness. Continuous Fiber Reinforced Thermoplastic (CFRT) laminates, with their characteristics of lightweight, high strength, corrosion resistance, and recyclability, are gradually being widely applied in transportation, aviation, energy, marine, and other fields. However, the full utilization of material performance is inseparable from precise and efficient molding processes.

Entering the Industry 4.0 era, the introduction of intelligent production, data-driven manufacturing, automated control, and Internet of Things (IoT) technologies is fundamentally transforming the production mode of CFRT thermoplastic laminates. This article will deeply analyze the principles and characteristics of their high-performance molding processes, and explore how Industry 4.0 technologies empower the production system to achieve a new pattern of stable quality, improved efficiency, and cost optimization.

I. Material Composition and Molding Fundamentals of CFRT Thermoplastic Laminates

1. Material Structure

CFRT thermoplastic laminates are composed of continuous fiber fabrics or unidirectional tapes and a thermoplastic resin matrix. Common fibers include carbon fibers, glass fibers, aramid fibers, etc.; thermoplastic resins include polypropylene (PP), polycarbonate (PC), polyetheretherketone (PEEK), polyamide (PA), etc.

Fibers provide high strength and rigidity.
The resin matrix imparts toughness, corrosion resistance, and processing plasticity.

2. Fundamental Molding Principles

The core of the molding process lies in heating CFRT semi-finished products (prepregs or preformed panels) to the resin melting state at a controlled temperature, then pressing them into the desired shape under high pressure, and finally cooling and solidifying them. The entire process is extremely sensitive to parameters such as temperature, pressure, heating rate, and cooling rate.

II. Mainstream Molding Processes and Their Characteristics

1. Compression Molding

This is the most widely used process for CFRT panels. Cut blanks are placed into a heated metal mold and rapidly formed under high pressure.

Advantages: Short cycle time (30 seconds–2 minutes), suitable for mass production, high dimensional accuracy.
Applications: Automotive interior and exterior parts, rail transit inner panels, home appliance housings, etc.
Process Key Points: The heating temperature must be precisely controlled within ±3°C around the resin melting point to prevent material degradation or incomplete molding.

2. Vacuum Forming

The panel is heated to the softening temperature, and then vacuum suction is used to attach it to the mold surface for molding.

Advantages: Low equipment cost, suitable for large structural parts.
Disadvantages: Difficult to control thickness uniformity, suitable for parts with moderate structural strength requirements.
Applications: Large covers, decorative panels, bulkheads, etc.

3. Hot Plate Welding and Splicing Molding

The contact surfaces of panels are heated using a hot plate to melt the resin, then pressure is applied for bonding, enabling splicing without metal fasteners.

Advantages: High bonding strength, waterproof and corrosion-resistant.
Applications: Transportation vehicle floors, container panels, industrial enclosures, etc.

4. Automated Placement and Thermal Curing Integrated Molding (ATP/ATL)

Automated equipment is used to accurately lay continuous CFRT unidirectional tapes at designed angles, followed by overall heating and compaction.

Advantages: Structural performance can be customized according to needs, suitable for high-performance fields (such as aviation and military industry).
Disadvantages: High equipment investment, high requirements for operation and maintenance.

III. Empowerment of Industry 4.0 Technologies for CFRT Molding

The core of Industry 4.0 is "intelligence, dataization, and interconnection". By deeply integrating production with information technology, it realizes the whole-process optimization from raw materials to finished products. For CFRT thermoplastic laminates, this integration is reflected in the following aspects:

1. Intelligent Temperature and Pressure Control Systems

Through sensors and closed-loop control systems, real-time monitoring and dynamic adjustment of mold temperature and pressure are achieved. For example, embedding a thermocouple array in the press allows real-time collection of temperature distribution at different positions, and automatically adjusts the power of heating elements to ensure uniform heating of the material.

2. Online Quality Monitoring

Using non-destructive testing methods such as infrared thermography, ultrasonic testing, and laser scanning, defects such as bubbles, delamination, and fiber misalignment inside the panel are detected in real time during production. Process parameters are corrected immediately to reduce the scrap rate.

3. Automated Logistics and Production Rhythm Optimization

Combining Automated Guided Vehicles (AGVs) and robotic arms, automatic transportation of semi-finished products between processes such as heating, molding, cutting, and surface treatment is realized. This ensures stable production rhythm and reduces errors caused by manual handling.

4. Data-Driven Process Optimization

By combining historical production data with machine learning algorithms, the molding performance of different batches of raw materials is predicted, and optimal heating temperature curves and pressure application strategies are automatically recommended to achieve personalized process adjustment.

IV. Quality Control and Performance Assurance

1. Raw Material Consistency Testing

CFRT prepregs or semi-finished products entering the production line are tested for tensile strength, surface quality, resin content, etc., to ensure batch stability.

2. Standardization of Process Parameters

Standard ranges for parameters such as temperature, pressure, and time are formulated, and real-time recording and traceability are conducted through a Manufacturing Execution System (MES).

3. Finished Product Testing and Certification

Finished products must undergo comprehensive performance tests including bending strength, impact toughness, heat resistance, and dimensional accuracy, and meet ISO, ASTM, or specific industry standards (such as EN 45545, FAR 25.853, etc.).

V. Future Trends and Development Directions

1. Fully Automated Flexible Production

Through modular production units, rapid switching of panels of various specifications and shapes on the same production line is realized, improving market response speed.

2. Digital Twin Factory

A virtual factory model is used to simulate the entire production process, predict output, energy consumption, and quality distribution, and optimize the layout and processes before actual production.

3. Green Manufacturing

The introduction of degradable resins, low-energy heating systems, and material recycling lines reduces the carbon footprint and realizes the whole-life-cycle environmental management.

4. AI-Driven Adaptive Processes

In the future, CFRT panel production will be able to automatically adjust parameters such as temperature, pressure, and pressing time based on real-time detection data without human intervention, achieving a true "dark factory" production mode.

Conclusion

CFRT thermoplastic laminates are not only a material innovation; the combination of their high-performance molding processes and Industry 4.0 will further unlock their potential in various industries. The introduction of intelligent manufacturing technologies comprehensively improves production efficiency, quality stability, and customization capabilities, making this material expected to become a backbone force for global lightweighting and sustainable development in the next decade.

With the continuous deepening of digitalization and intelligence in manufacturing, CFRT thermoplastic laminates will usher in a new era of simultaneous growth in production capacity and technology.

Key words:

The strategic value of CFRT thermoplastic laminates in sustainable development and circular economy

CFRT thermoplastic laminates are a game-changer in the future of transportation

The strategic value of CFRT thermoplastic laminates in sustainable development and circular economy

CFRT thermoplastic laminates are a game-changer in the future of transportation