Impregnation machine

Processing Solution
The Xplore Tow Impregnation Line is a compact laboratory-scale system for the rapid development and screening of continuous fibre-reinforced thermoplastic filaments, using only minimal amounts of material. Fully integrated with Xplore Micro-Compounders, it lets researchers formulate new polymer compounds and convert them directly into impregnated continuous fibre filaments, ready for evaluation.

Key benefits

• One integrated workflow: material formulation and precision melt impregnation in a single system, with no material transfer between steps.
• Minimal material use: screen new formulations from minimal material quantities, cutting development time and cost.
• A clear path to scale-up: validate composite feedstock performance before committing to industrial production.

Capabilities

• Fibre Compatibility: Process carbon, glass, aramid, basalt, UHMWPE, natural, and metallic fibres.
• Material Compatibility: Process PP, PA, PC, PET, TPU, PEEK, PEI, PPS, and other thermoplastics.
• Composite Filament Production: Produce continuous fibre-reinforced thermoplastic filaments for additive manufacturing and evaluation.
• Process Optimization: Optimize fibre spreading, impregnation, consolidation, and composite performance.

Key Features

• Controlled Fibre Handling: Tension-controlled unwinding and guiding.
• Precision Impregnation: Interchangeable die dimensions and in-melt fibre spreading.
• Adjustable Processing: Tunable line speed and haul-off control.
• Controlled Winding: Torque-controlled take-up winding.
• Process Monitoring: Real-time process visualization and monitoring.

Research Areas

• Fibre-Reinforced Filaments: Continuous fibre composites with engineering and high-performance thermoplastics.
• Fibre–Matrix Studies: Fibre spreading, impregnation, and interface optimization.
• Lightweight & Sustainable Composites: High-performance and sustainable composite systems.
• Composite Quality: Fibre volume fraction, void content, and uniformity.
• Process & Scale-Up: Process optimization, material validation, and scale-up.

Applications

• Composite Additive Manufacturing: CFAM and 3D composite printing.
• Lightweight Structures: Automotive, aerospace, UAV, and robotic applications.
• Pressure & Containment: Pressure vessels, pipes, and containment structures.
• Medical & Wearable Composites: Prosthetics, orthotics, and wearable devices.
• Advanced Composite Design: Fibre-path, consolidation, and load-oriented structure development.

MC Xperience comparison table
Specification | MC Xperience 5 | MC Xperience 15 | MC 15 HT (Vari‑Batch®) | MC 40
Batch volume (ml) | 5* | 15 | 15 | 40
Max. torque (Nm) | 10 (15**) | 15 (20**) | 40 | 40
Torque per volume (Nm/ml) | 2 (3**) | 1 (1.3**) | 2.7 | 1
Max. temperature (°C) | 350 (425**) | 350 (425**) | 475 | 425
Screw Rotation Mode | Co‑rotating (counter‑rotating**) | Co‑rotating (counter‑rotating**) | Co‑ / counter‑rotating standard | Co‑ / counter‑rotating standard
Screw speed (rpm) | 1–425 | 1–425 | 0.1–500 | 0.1–500
Active cooling | Manual and optional | Manual and optional | Automated standard | Automated standard
Application focus | Reliable small‑scale micro‑compounding & cost‑effective R&D | Reliable micro‑compounding & cost‑effective R&D | High‑end micro‑compounding with challenging systems for advanced R&D | High‑volume batch & continuous micro‑compounding
*Custom; up to 10
**Upgrade options

Technical specifications

• Compact laboratory-scale tow impregnation line for continuous fibre-reinforced thermoplastic filaments.
• Integration with Xplore Micro-Compounders enabling direct formulation-to-filament workflow.
• Compatible with a wide range of fibres: carbon, glass, aramid, basalt, UHMWPE, natural and metallic fibres.
• Compatible with common and high-performance thermoplastics: PP, PA, PC, PET, TPU, PEEK, PEI, PPS, etc.
• Precision impregnation via interchangeable die dimensions and in-melt fibre spreading.
• Tension-controlled unwinding, tunable line speed, haul-off control, and torque-controlled take-up winding.
• Real-time process visualization and monitoring to optimize impregnation, consolidation and composite quality (fibre volume fraction, void content, uniformity).
• Designed for minimal material use to enable rapid screening of new polymer formulations and a clear path to scale-up for industrial production.