Composite materials are a combination of several elements – generally a reinforcement material made of carbon or glass fibers combined with a matrix material. The matrix material acts as a binder that permeates the reinforcement and helps to solidify into the final shape. The combo of these two materials, in essence creates a third, known as a composite.

Historically, nearly all composite materials have been made from thermoset based materials. This includes all of the composite golf shafts, bike frames, wind turbine blades, car and airplane parts that you have seen. With near certainty, these parts were manufactured by hand, a long and expensive process. In its simplest terms, a thermoset is a family of polymers that undergoes a chemical reaction for it to reach its ultimate performance. During this chemical reaction, a process called “crosslinking” occurs, and longer molecular chains result, causing the material to solidify. This chemical crosslinking is permanent and irreversible. Crosslinking results in thermoset materials being sensitive to time and temperature.

The other family of polymers is called thermoplastics. Thermoplastics differ from thermosets in a number of ways, but the key differentiator is how they behave when heated and cooled. Thermoplastics can be heated to their melting point, where they become liquid and supple. Upon cooling, they again become solid, taking on the desired shape. By controlling the shape and cooling of a thermoplastic, functional parts with excellent properties are created. The process of heating and solidifying can be repeated; enabling subsequent welding and recyclability. We are surrounded by items made from thermoplastics – they have enabled how we interact with almost all everyday objects.

By combining thermoplastics with a reinforcing material like carbon, glass, or even natural fibers, we are able to add another layer of performance to these versatile materials. The combination of a reinforcement fiber and a thermoplastic is what makes a thermoplastic composite. Given that thermoplastics are able to be re-melted and have inherently excellent deformation, they excel at toughness.

At Bias Ply, LLC, we wake up and think about new applications and processing techniques for how to better use advanced materials in everyday life. We are able to help select the best material for your application and aid in designing and prototyping initial concepts. Let us help you.

Composites are extremely lightweight while offering very high stiffness and strength. When comparing specific strength (strength/density) of thermoplastic composite materials to other materials (such as aluminum, stainless steel, and titanium), composites have much higher performance in this area. The combination of strength and stiffness with low density combines to create a stronger and lighter outcome.

Reuse of traditional thermoset materials is hindered by an irreversible chemical reaction. Once created, thermoset materials must be processed relatively quickly. This results in a lot of scrap and waste during manufacturing, and finished parts heading to the landfill at their end of life, versus being recycled.

Alternatively, thermoplastics can be reheated and reshaped multiple times into new forms. Scrap and finished parts can be made into materials for other downstream processes and applications. The reusability of this material is far greater than thermoset plastics commonly used in manufacturing, and is an exciting alternative.