German chemical producer Evonik (Essen; www.evonik.com) has developed a new process called the “PulPress” method that it believes will enable composites producers to scale up production and tap into new markets beyond high-end components. The process, which combines compression moulding and pultrusion, is also claimed to reduce production costs by up to 60%, especially as compared with methods such as resin injection. The new method was developed using the company’s “Rohacell” temperature-resistant high-performance rigid structural polymethacrylimide foam.

Evonik said Rohacell has already proven its merit as a lightweight yet rigid material as it retains its shape particularly well. The PulPress process works by weaving fibres around the foam core before impregnating them with resin and subsequently compressing the complete system into the desired shape at high temperature and pressure. This even allows manufacturers to produce complex geometries and integrate recessed areas for threaded components or other fixtures, the company said.

Beyond cost efficiency, Evonik said “particularly impressive” aspects of the process are its design flexibility and the crash behaviour of the resulting composite parts, claimed to be about 75% lighter than those manufactured from steel. “These advantages have already won over a large number of customers in the European automotive industry," said Sivakumara Krishnamoorthy, manager for new applications at Evonik Resource Efficiency. The Essen-based company said manufacturers outside the automotive industry are also showing interest in PulPress.

Conceivable new commercial applications are seen in aircraft construction as a cost-effective method of producing large numbers of carry-over parts. The Asian aviation industry already is using Rohacell in the regional jet "ARJ21-700" and the prototype of China’s first large commercial airliner, "C919", due to enter into commercial service in 2018, Evonik said at the start-up of its new production facility in Shanghai / China last year – see Plasteurope.com of 11.02.2016. Another application could be in lightweight sandwich cores, now gaining importance in the production of sports equipment. The company will exhibit the new technology at the upcoming “JEC World” composites show in Paris / France from 14-16 March.

In November 2016, Evonik said it would expand capacity for Rohacell at its Darmstadt / Germany, site by about 20% in response to double-digit global demand growth – see Plasteurope.com of 23.11.2016. The additional capacity should be on stream from the second half of this year. Neither capacity nor investment costs have been disclosed. The German company also operates a Rohacell plant at Mobile, Alabama / USA.