PROCESSES

We operate various manufacturing processes, ranging from aqueous impregnation and melt impregnation for unidirectional (UD) tape production to fabric prepreg and CCM (continuous compression molding) for large laminate sheets and profiles. Our integrated capabilities allow us to manage the complete lifecycle of thermoplastic carbon fiber components, from raw materials to  finished products.

1. Aqueous Impregnation (UD Tape)

This process combines carbon fibers with a resin suspension (slurry). Through precise impregnation, heating, and setting, we produce UD tapes with neatly aligned fibers, making them an ideal substrate for high-performance composite manufacturing.

2. Hot-Melt UD Tape Impregnation

By laminating high-performance resin films with carbon fibers and applying heat-fusion impregnation, we create UD tapes with stable and reliable mechanical properties. This process is highly efficient and optimized for industrial scale.

3. Fabric Prepreg (Powder Scattering / Film Lamination)

Using either powder coating or film lamination technology, resin is applied to the surface of carbon fiber fabrics. Subsequent heating melts the resin to fully impregnate the fibers, resulting in uniform, high-quality thermoplastic prepregs.

4. CCM (Continuous Compression Molding)

Hansu has filled a significant technical gap in the industry with its Continuous Compression Molding (CCM) lines. This process continuously feeds prepreg into molds for integrated heating and pressure molding, enabling the high-efficiency mass production of long-dimension composite profiles and plates.

5. Thermoplastic Compression Molding

Thermoplastic prepregs are placed in a mold, heated until softened, and then pressurized into shape. This method is perfectly suited for the mass manufacturing of components with complex geometries.

6. Overmolding / Integrated Molding-Injection

This advanced hybrid technology integrates overmolding with compression-injection processes. By combining the high strength of continuous carbon fiber components with the structural flexibility of plastic injection parts, we significantly enhance product integration and overall structural integrity.

7. Thermoplastic Filament Winding

Thermoplastic prepreg tapes are wound onto a mandrel at specifically designed angles and then consolidated through heating. This process is ideal for rotational-symmetric components such as high-pressure vessels, pipes, and tubes.

8. Automated Fiber/Tape Placement (AFP/ATL)

Utilizing 8-axis robotic automated systems, we precisely lay thermoplastic prepreg filaments or tapes layer-by-layer according to the component's design. This high-precision technology is capable of manufacturing various composites with complex curved surfaces for aerospace and automotive applications.