Structural Thermoplastics

Alfond Advanced Manufacturing Lab for Structural Thermoplastics

The Alfond Advanced Manufacturing Laboratory for Structural Thermoplastics accelerates manufacturing with digital, additive, and robotics technologies to cut costs and cycle times. Thermoplastic composites are lightweight, recyclable, corrosion-resistant, and strong enough for structural applications in defense, automotive, aerospace, marine, and consumer goods.

ASCC’s state-of-the-art lab features 3D printing, thermoforming, a fast-reaction molding press, an advanced tape layup machine, and a dual robotic manufacturing cell. In partnership with industry, it drives thermoplastic research, testing, and workforce training.

Rapid Prototyping Development

We work with corporations, government agencies, and academic institutions of all sizes to partner on research, development, and commercialization projects, such as:

Manufacturing process and tooling design and development
Proof of concept demonstration and economic analysis
Reengineering metals and thermosets into thermoplastic composites
Joint U.S. research and development funding opportunities

Contact us

Facilities and Capabilities

The Dieffenbacher FiberForge RELAY 2000 automates the rapid and efficient placement of fiber-reinforced thermoplastic tapes, creating highly customizable blanks. Using a vacuum-secured rotating motion table, this system stacks and ultrasonically welds multiple layers, ensuring precise fiber orientation. Supporting two thermoplastic tape types with widths ranging from 50mm to 150mm, the process results in parts up to 60% lighter than steel and 30% lighter than aluminum. The system’s speed and material efficiency significantly reduce production costs and cycle times, making it ideal for aerospace, automotive, and other lightweight structural applications.

The thermoforming cell rapidly heats and molds tailored blanks into structural components. A rail-mounted ABB 6650S Industrial Robot transports blanks to the Sopara Infrared Oven, which can reach temperatures up to 450°C (842°F) and accommodate parts up to 1000mm x 1600mm. Once heated, blanks are transferred to a 650-ton Utah Hydraulic Press with 1800mm x 1200mm heated platens and built-in cooling channels for rapid solidification. This process enables fast prototyping and high-volume production of complex thermoplastic parts, meeting industry demands for lightweight, durable components.

The lab’s post-processing and prototyping capabilities enhance efficiency and precision in final part production. The ABB IRB 4400 and IRB 6650S industrial robots handle grinding, ultrasonic welding, and drilling, streamlining post-production. The Stratasys Fortus 900mc 3D printer produces high-precision prototypes, tooling, and end-use parts using a variety of thermoplastic materials. With OpenAM compatibility and a high-temperature chamber, the system supports rapid prototyping and advanced material evaluation for aerospace and industrial applications.

Tape Lay-up Cell

Dieffenbacher FiberForge Relay 2000 Automated Tape Lay-up Machine:

The RELAY Station 2000 includes a rapid tape dispensing system, which feeds composite tape through a track positioned above a two-axis motion table. Develops custom tailored blanks of fiber-reinforced resin-impregnated thermoplastic tapes over a +/- 180 degree rotating and translating vacuum suction motion table which can range in width from 50-150mm (2-6”).

Thermoforming Cell

Techni Modul – 6,400 kN Hydraulic Press:

Accommodates a wide range of mold designs with its 1800mm x 1200mm (71inch x 47inch) T-slotted upper/lower heating plates and an opening distance of up to 1100mm (43inch). Built in forced convection cooling channels for rapid mold/blank cooling to achieve required crystallinity.

Techni-Modul – Infrared Oven:
This custom designed Infrared oven can range in temperature from 50-450°C (122-842°F) and can fit blanks as large as 1800mm x 1200mm (71inch x 47inch) on its automated wire mesh drawer.

ABB – IBB 6650S Industrial Robot:

This 125kg capacity industrial robot is installed on a trolley which travels on rails to allow it to traverse from cell to cell. The robot is equipped with a quick tool changer, allowing an automatic and fast connection with several tools.

High-Temperature AM Tooling and Prototyping

Stratysys Fortus F900:

The Fortus F900 3D Production system prints accurate, repeatable parts as large as 914 x 610 x 914 mm (36 x 24 x 36 in.). With several fully calibrated printable materials, and OpenAM ready for printing open source materials, this printer is suitable for evaluating R&D materials, building fixtures and factory tooling, and fabricating end-use parts, as well as the most demanding functional prototypes. The high oven temperatures (up to 220C) and fine resolution (as small as 0.005″ slice height) make this printer an ideal solution for printing high-temperature AM tooling, and aerospace components.

Stratasys Fortus 900mc

Can 3D print parts up to 36” x 24” x 36”

The system incorporates a fully enclosed and thermally regulated fused deposition modeling (FDM) process, which allows for controlled cooling rates between layers, higher dimensional accuracy and heightened layer diffusion.

The thermoplastic filament is heated inside the printer until a semi-liquid, molten state is achieved, and then it is extruded in beads along the toolpath.

Slice heights range from 0.005” to 0.020”, with tight tolerance of +/- 0.0035” in the x and y directions and +/- 0.0035” + slice height in the z direction.

Offered Materials

ABS-ESD7, ABSi, ABS-M30, ABS-M30i, ASA, HIPS, Nylon 6, Nylon 12, Nylon 12 with Carbon Fiber, Polycarbonate (PC), PC-ABS, PC-ISO, Kimya Fire-Retardant PC, Polyphenylsulfone (PPSU), ULTEM 9085, ULTEM 9085 Consumer Grade, ULTEM 1010, ULTEM 1010 Consumer Grade, Antero (polyetherketoneketone [PEKK]), Carbon Nanotube Antero. VICTREX AM200 Polyaryletherketone (PAEK), and Sacrificial Model Materials.

OpenAM

OpenAM software module allows for use of over-the-counter thermoplastics filaments. Standard 1.75 mm +/- 0.05 mm filaments accepted.

Offering industry partnerships for process development, material testing, and commercialization.

Contact the ASCC

Advanced Structures & Composites Center