Challenge
Continuous fiber-reinforced thermoplastics are transforming modern manufacturing, especially in industries such as automotive engineering, where lightweight yet durable materials are essential. These advanced composites combine high mechanical strength with reduced weight, enabling innovative designs and improved performance.
However, manufacturing these materials presents significant challenges. One of the most critical issues is achieving rapid and uniform heating of organo sheets—semi-finished materials made of fibers such as glass, carbon, or aramid embedded in a thermoplastic matrix.
During thermoforming and injection molding, temperature inconsistencies can lead to:
- warping and deformation
- uneven material flow
- inconsistent mechanical properties
- reduced product quality
Precise temperature control is therefore essential to ensure reliable and repeatable production outcomes.
Solution
To address these challenges, advanced infrared (IR) temperature measurement and control systems are integrated directly into the manufacturing process.
Companies like KraussMaffei utilize infrared pyrometers—such as Optris CT LT22—within IR heating zones to monitor surface temperatures of organo sheets in real time. These sensors are strategically positioned behind infrared heaters to continuously measure temperature across the material.
The collected data is transmitted to intelligent control systems that automatically adjust heating zones, ensuring uniform temperature distribution across the entire surface.
This real-time, closed-loop control enables:
- precise heating regulation
- rapid response to temperature deviations
- consistent process stability
Understanding the FiberForm Process
The FiberForm process combines thermoforming and injection molding into a single, efficient production step.
The process begins with organo sheets, which consist of continuous fibers embedded in thermoplastic materials such as polyamide or polypropylene.
Key stages include:
- Heating – organo sheets are rapidly heated using infrared radiation
- Thermoforming – the heated material is shaped into the desired geometry
- Back-injection molding – additional material is injected to reinforce and complete the part
This integrated process allows manufacturers to produce complex, lightweight, and high-strength components in short cycle times.
How Infrared Temperature Control Works
Infrared heating systems equipped with multiple heating zones ensure that organo sheets are heated evenly and quickly.
Each heating zone is monitored by a dedicated pyrometer, which continuously measures surface temperature. These sensors operate reliably even in high ambient temperatures and harsh industrial environments.
Key system features include:
- multi-zone temperature monitoring for full-surface control
- real-time feedback loops for automatic heating adjustments
- integration with industrial control systems via standard signals (e.g., 4–20 mA)
- durable sensor design for high-temperature operation without cooling
Optional features such as air purge systems protect sensor optics from dust and contamination, ensuring long-term reliability.
Benefits
Implementing infrared monitoring in fiber-reinforced thermoplastic manufacturing delivers significant advantages:
- consistent and uniform temperature distribution
- prevention of defects such as warping or weak bonding
- improved product quality and mechanical performance
- reliable, uninterrupted large-scale production
- real-time process control and adaptive heating
Technology Advantages
Modern infrared pyrometers provide key capabilities for demanding production environments:
- non-contact temperature measurement
- high accuracy and fast response times
- compact sensor design for easy integration
- resistance to high ambient temperatures (up to 180°C)
- reliable operation in harsh industrial conditions
Additionally, separating the sensor head from the electronics allows flexible installation and improved durability.
Efficiency and Process Optimization
By integrating infrared temperature monitoring into heating systems, manufacturers gain full control over the thermoforming process.
Continuous data collection enables:
- precise control of heating profiles
- reduction of production variability
- improved process repeatability
- optimization of cycle times
This leads to lower production costs, reduced waste, and higher throughput.
Advancing Composite Manufacturing
As industries increasingly adopt lightweight composite materials, the need for precise and reliable manufacturing processes becomes critical.
Infrared temperature monitoring provides the accuracy and responsiveness required to meet these demands. By ensuring uniform heating and real-time process control, manufacturers can fully leverage the advantages of continuous fiber-reinforced thermoplastics.
The result is stronger, lighter, and more reliable components, supporting innovation and efficiency in modern industrial production.
