Providing light weight components using Thermoplastic Composites
Cato Composites offers expert experience in the application of thermoplastic composite material in areas such as consumer and sporting goods, aerospace, anti-ballistic products and specific automotive components. Cato Composites founded in 2008 relies on over 20 years of experience in the world of thermoplastic composite materials, processing and applications.
Our thermoplastic composite components find application in high-volume end products in a wide range of industries. The drivers for using our composite components is “enabling lightness” by: metal replacement, reinforcement of injection moulded components, energy absorption, durability and fatigue resistance and the ability to provide components in large quantities. Material comprise the use of Carbon, Glass and Aramid fibre reinforced material. Self Reinforced Composites such as SrPP and SrPET as well as biobased and circular composites materials.
Cato starts analysing application and select materials and processes for manufacturing. After an initial feasibility phase resulting in a preliminary product specifaction, Cato opens tool and manufactures parts for acceptance of large series production. Cato operates an in-house tool shop guided by our development team.
Cato has a unique set-up and focus to enable development, manufacturing and supply of thermoplastic composite components and products. Our manufacturing processes comprise 4 steps from material lamination and consolidations, automated thermoforming and fast compression molding, CNC robotic precision trimming and finishing, assembly and QA/QC. We have programs to continuously improve our manufacturing capabilities.
1) Carbon tree climbing shank:
The development and manufacturing of a CFRTP UD tape based Carbon shaft tree climbing shank replacing forged aluminium component with 50% weight saving. The establishment of a new fast compression moulding process for the efficient volume manufacturing of forged UD Carbon components.
Advantages: net shaped moulding
Materials: unidirectional Carbon with thermoplastic
System and process: Cato fast compression moulding process
Further details (weight, surface quality, costs): high surface
Development status: Completed development, manufacturing and supply
Development partners: Covestro
2) CFRTP parts with integrated digital print and high definition surface finish:
The development and manufacturing of a CFRTP based composites material with integrated full colour and scratch resistant digital printing solution.
Advantages: light weight CFRTP components with integration of surface finish and printing
Materials: unidirectional glass thermoplastic matrix
System and process: Cato high speed thermoforming process and digital printing
Further details (weight, surface quality, costs): weight, full integration of digital printed surface
Development status: Completed development, manufacturing and supply
Development partners: Cato proprietary technology
3) Biobased and circular thermoplastic composite components:
The development and manufacturing of furniture components from 100% biobased materials and circular textile materials with Cato fast compression moulding process.
Advantages: biobased and circular product solution
Materials: flax/PLA and recycled cotton textile/PLA
System and process: Cato fast compression moulding
Development status: Completed development, manufacturing and supply
Development partners: Planq, Christien Meinderstma
4) Self Reinforced PP composite materials (SrPP) and parts:
The development and manufacturing of ultra light weight components from Self Reinforced Polypropylen Composite material (SrPP). The integration of a scratch resistant and digitally printed surface finish and the possibility of the integration of a textile surface finish on the materials and parts.
Advantages: ultra light weight, lighter then Carbon composite solution
Materials: Self reinforced PP material
System and process: Cato lamination and consolidation, Cato fast compression moulding and Cato fast thermoforming
Further details (weight, surface quality, costs): <0,9 kg/l density, scratch and digital printed surface
Development status: manufacturing
Development partners: Cato proprietary technology
5) Hybrid aircraft interior components:
The development of hybrid structural components for aircraft interior such as seating structures. Use of PEI en PPS based carbon and glass fibre thermoplastic composites and injection molding materials.
Advantages: 50% weight saving vs. forged aluminum components; Integrated structural items by using overmoulding
Materials: Glass and Carbon fibre with PEI or PPS
System and process: Cato lamination and consolidation, Cato fast compression moulding and Cato fast thermoforming and injection moulding
6) Anti-ballistic thermoplastic composite military helmets and parts for personal protection:
The manufacturing of aramid based military helmet shells complying with NIJ IIIa standards. The manufacturing of anti-ballistic products using SrPP material.
Advantages: High ballistic performance, constant quality
Materials: Aramid and PA, SrPP materials
System and process: Automated manufacturing of military helmet shells
Development status: Manufacturing
Development partners: Rofi AS
Contact details
www.cato-composites.com
6991 GS Rheden
The Netherlands
