Thermoset composites combine polymers with fibers, such as glass or fabric. They are suitable for various applications, particularly those requiring high heat, chemical exposure resistance, or exceptional strength. Atlas Fibre is one of North America’s largest thermoset distributors and manufacturers. We have more than $8 million worth of inventory in stock at our facility in Illinois and access to additional raw materials at our partner facilities. Learn more about our thermoset composite manufacturing process and how we can work with your company.
Once thermoset materials are cured and hardened, they are set in that form and cannot be melted down or turned into another form.
Thermoset manufacturing heats the fibers and polymers until they are in a liquid state. Then, they are formed into a shape and allowed to cool. While hardening, the polymers start to crosslink, curing the material and creating an irreversible chemical bond.
Because of their chemical makeup, thermoset materials can’t be warped, softened, or melted.
The composite manufacturing process has several forms. Each type typically results in a different shape or creates different material properties.
In high pressure lamination, prepreg is placed into a press and heated under pressure to form a highly durable and strong composite sheet. High pressure lamination is the process by which materials such as G-10, FR-4, Linen Phenolic, and Paper Phenolics are produced.
During compression molding, heat and force turn materials into a defined shape. Usually, compression molding uses metal dies on a molding press to create the finished material shape. Compression molding is typically used to create larger parts with high dimensional stability.
Injection molding is often used in the manufacturing of thermoplastics, but may occasionally be used to produce thermoset materials. During the process, a thermoset material is pushed into a heated mold and allowed to cure. After curing, the part is removed from the mold and finished. Injection molding is typically used to produce high-volume, smaller components.
The closed mold manufacturing process involves spreading resin over a glass mat, then loading it into a press. The combination of heat and pressure cures the material.
During pultrusion, bundles of fiber get pulled through a resin. The fiber is then pulled into a heated die using a device for continuous pulling. The material forms and cures as it passes through the die before being cut to the appropriate length.
Similar to pultrusion, filament winding passes fibers through a resin bath before winding them onto a spindle to achieve the desired thickness. Heat cures the spindle and fibers, creating a tube.
Altas Fibre is a composite material manufacturer with facilities in the U.S. and India. We’re the dominant supplier of thermoset composite laminate in North America due to our extensive inventory of stock materials and shapes.
We also have extensive machining and fabrication capabilities. We can machine all types of thermoset composites and almost every kind of thermoplastic.
We want to help you reduce your project’s complexity and cost. We’ll act as your resource center, helping you choose the best material and manufacturing process for your needs. To learn more, contact us for a quote today.
