The University of Sheffield Advanced Manufacturing Research Centre (AMRC) has announced the UK’s first open-access, hybrid fibre reinforced thermoplastic tape development capability to accelerate innovation in sustainable composites technologies.

The dedicated research platform will feature a dual-mode thermoplastic processing line, designed and built by fibre handling and converting technology specialist Cygnet Texkimp to provide direct melt and slurry-based processing capability for a wide range of polymers and applications. 

The line also incorporates Cygnet Texkimp’s Flatline creel and fibre spreading technologies to maximise the range of fibres that can be processed, and to facilitate the development of novel composite tapes for downstream processing into composite components for industry.

Dr Gary Foster, senior technical fellow - thermoplastic composites at the AMRC, said: "This open access capability will provide material and tape suppliers, as well as downstream composite manufacturers the opportunity to develop novel tapes for their end-users. Leveraging the AMRC's expertise in advanced manufacturing and materials processing, this initiative will facilitate more in-depth research into sustainable composites and provide a better understanding of key processing parameters."

Thermoplastic composites offer several advantages, including recyclability, high performance, adaptability and efficiency. They are known for their lightweight, strong and impact-resistant properties and can be easily moulded and reshaped. Their ability to be recycled and repurposed at the end of their life cycle contributes to sustainability. Furthermore, with almost unlimited shelf life and compatibility with automated processes, thermoplastics eliminate extended cure times, reduce errors and make them ideal for high-volume production.

The hybrid line will be installed at the AMRC’s Factory of the Future facility where businesses and researchers will be able to develop new processing methodologies for novel thermoplastic composite intermediate tapes on a small-industrial scale with support from the AMRC. 

Andy Whitham, director of process development at Cygnet Texkimp, said: “The AMRC’s new thermoplastics research capability will provide a world-class testbed for businesses to explore the opportunities offered by these novel composites and adds considerable capacity and expertise to the UK’s composites manufacturing capability.

“Our hybrid line provides extensive control of the processing parameters for thermoplastic materials development. It will allow organisations to fully develop new processes and products on a small-industrial scale and prove out their concepts before investing in machinery.”

The dual-mode line allows industrial-grade polymers such as Polypropylene, nylons and PEEK to be processed from pellets using Cygnet Texkimp’s direct melt impregnation technology or powdered polymers to be processed using water-based slurries. The line is modular in design and allows rapid conversion between these two operating modes. 

The integration of Cygnet Texkimp’s Flatline creel and fibre spreading technologies enables processing of a range of fibres including carbon, glass, recycled and natural fibres. It can also be configured to produce composite tapes in a variety of widths from 45mm up to 180mm and with a specific fibre and polymer weight per metre.

The line and tape slitter will be installed towards the end of 2025 and will operate from early 2026. Industry and supply chain organisations interested in accessing the AMRC’s thermoplastic development capability can get in touch here.