Tape extrusion line UD

laboratorycompactfor thermoplastics

Processing solution
The Xplore UD Tape Line is a compact laboratory-scale benchtop system that converts formulated thermoplastic compounds directly into continuous unidirectional (UD) tapes. Fully integrated with Xplore Micro-Compounders, it enables rapid screening of new formulations using minimal material while providing representative tapes for characterization and scale-up studies.

Capabilities

• Material compatibility: carbon, glass, aramid, basalt, UHMWPE, natural and metallic fibres with commodity, engineering, bio-based and high-performance thermoplastics.
• UD tape production: continuous tape output suitable for characterization, overmoulding, ATL/AFP feedstock and scale-up evaluation.
• Controlled impregnation: consistent fibre wet-out, low void content and optimized spreading.
• Process optimization: adjustable tape width, fibre volume fraction and line parameters to evaluate manufacturing windows.

Key Features

• Compact & modular: benchtop system designed for laboratory R&D and materials development workflows.
• Controlled fibre handling: tension‑controlled unwinding and configurable spreading.
• Precision impregnation: temperature‑controlled, hardened tool‑steel die for repeatable wetting.
• Adjustable processing & collection: tunable line speed, haul‑off control and torque‑controlled winding for stable winding and collection.
• Process monitoring: intuitive real‑time software with optional pressure transducer for inline observation.

Research Areas

• Material development: formulation of advanced thermoplastic matrices and hybrid UD tapes.
• Fibre–matrix optimization: spreading, impregnation, adhesion and interface studies.
• Sustainable composites: bio‑based, natural‑fibre, recycled and recyclable systems.
• Tape processing: feedstock development and tape‑quality optimization for ATL and AFP.
• Downstream & scale‑up: overmoulding, thermoforming, joining, welding and mechanical performance studies.

Applications

• Transport & aerospace: lightweight components for automotive, aerospace, rail, marine and UAVs.
• Energy & pressure systems: hydrogen vessels, tanks, pipes, EV battery structures and renewable‑energy parts.
• Industrial & infrastructure: robotics, automated equipment, machinery and structural reinforcement.
• Hybrid structures: overmoulded parts, thermoplastic sandwich panels and hybrid components.
• Medical & consumer products: devices, prosthetics, sporting goods and high‑performance consumer items.
• Recyclable structures: components designed for recycling with thermoplastic matrices.

Technical specifications

• Product: UD Tape production line (laboratory‑scale thermoplastic UD tape system)
• Integration: direct workflow with Xplore Micro-Compounders for formulation‑to‑tape conversion
• Materials: carbon, glass, aramid, basalt, UHMWPE, natural and metallic fibres; compatible with commodity, engineering, bio‑based and high‑performance thermoplastics
• Output: continuous UD tapes for testing, ATL/AFP feedstock, overmoulding and scale‑up
• Fibre handling: tension‑controlled unwinding; configurable spreading
• Impregnation: temperature‑controlled impregnation with hardened tool‑steel die
• Process control: tunable line speed, haul‑off control, torque‑controlled winding; optional pressure transducer
• Software: real‑time monitoring and process logging for optimization