Technology
Core platforms driving ultra-thin composite innovation
Mechanical Fiber Spreading
Zloonex spreads carbon fiber down to 0.025 mm, producing single UD layers below 0.07 mm — 1/2 to 1/3 the thickness of standard tapes — while balancing raw-material flexibility with structural toughness.
Nano-Sizing Coloring Pretreatment
A proprietary pretreatment eliminates color fading during mechanical polishing, achieving Grade 0 coating adhesion (GB/T 9286, equivalent to ISO 2409) with industrial-grade color stability and translucent optical performance.
Suspension-Melt Prepreg Process
A unique combined process has achieved mass-scale production of ultra-thin continuous-fiber thermoplastic prepregs below 0.07 mm.
Processing Routes & Thermoformability
Optimized for compression molding, automated tape laying, and continuous tube winding; the thermoplastic matrix can be reheated and reshaped, enabling 100% recyclability and zero-waste manufacturing.
Material Systems Portfolio
Comprehensive thermoplastic matrix options for every application
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| Material System | Standard Specification | HDT (°C) | Core Applications |
|---|---|---|---|
| CF/PP (or GF/PP) | 30–60 wt%, 60–100 gsm, 0.06–0.12 mm | 80 – 120 | NEV interiors, appliance shells, UAV structures |
| CF/PA6 (or GF/PA6) | 30–60 wt%, 70–100 gsm, 0.06–0.12 mm | 120 – 150 | Automotive structural inserts, industrial gears, sports gear |
| CF/PC (or GF/PC) | 30–60 wt%, 60–100 gsm, 0.06–0.12 mm | 120 – 140 | 3C electronic housings, automotive lighting, optical parts |
| CF/PPS | 50–75 wt%, 70–120 gsm, 0.07–0.12 mm | 200 – 220 | High-temperature aircraft brackets, engine shields |
| CF/PEEK (or CF/TPI) | 60–75 wt%, 70–120 gsm, 0.05–0.12 mm | 240 – 280 | Space structures, medical implants, semiconductor equipment |
Note: The table above lists laminate / material-system specifications (HDT basis). UD tape specifications (0.07–0.20 mm, 25–40 wt% resin) are listed on individual product pages and differ by system. The UD tape family covers CF/PEEK, CF/TPI, CF/PA6, CF/PC, and CF/PPS matrices.
Technology & Cost Matrix
How Zloonex ultra-thin thermoplastics compare with standard alternatives
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| Performance Index | Zloonex Ultra-Thin Thermoplastics | Standard Thermosets (Epoxy) | Conventional Composites |
|---|---|---|---|
| Weight & specific strength | Extreme light weight (density halved); high specific strength and modulus | High strength; brittle failure profiles | Heavy structure; limited weight savings |
| Design & molding freedom | Excellent; automated tape laying and rapid molding | Limited; autoclave curing with long cycle | Poor; restricted to basic geometries |
| Impact / fracture resistance | Superb toughness; plastic deformation absorbs energy | Poor; prone to micro-crack propagation | Average; relies on thick-wall dimensioning |
| Lifecycle recyclability | 100% recyclable, re-meltable, green manufacturing | Non-recyclable; cannot re-melt | Hard to recycle; high processing energy cost |
| Mass production cost | Low cycle times, minimal waste, low unit cost | High labor and curing costs, high scrap rate | Double-high energy and labor inputs |
Thermoplastic UD Tape - Resin Matrix Grade Performance
Three production-grade matrices, one process. All grades are tow pre-impregnated in a continuous melt-impregnation step with no slitting, so fiber orientation and resin content stay uniform across the full tape width and roll length.
Thermal Conductive Tape
TPI / PEEK / PA6
Thickness-direction thermal conductivity reaches 5 W/mK.
Compatible with in-situ laser consolidation and hot molding.
CF / TPI UD Tape
Thermoplastic Polyimide
Long-term service temperature up to 260 °C.
Near-zero thermal expansion coefficient (CTE). Resistant to spatial radiation.
CF / PEEK UD Tape
Polyether Ether Ketone
Long-term loaded service at 180 °C.
Outstanding toughness, impact, delamination and fatigue resistance. Weldable and repairable.
Additional custom thermoplastic prepreg UD tapes available upon request. Widths and fiber content are OEM-adjustable.
Equipment & Manufacturing Process - Turnkey CFRTP Lines
Zloonex designs and manufactures its own production equipment. Every line below is developed and built in-house, so equipment capability and material know-how stay matched.
Two-Belt Laminate Press Line
Continuous two-belt flat laminate press for CFRTP sandwich and solid panel lamination, with selectable belt width and heated zones.
| Parameter | Value |
|---|---|
| Belt Width | 550 - 3200 mm |
| Compound Thickness | 0.5 - 100 mm |
| Conveyor Belt | Anti-static Teflon belt |
| Max Belt Pressure | 0 - 50 N/cm² |
| Heating Mode | Electric / Oil / Gas |
| Heating Zone Length | 500 - 6000 mm |
| Designed Speed | 0.5 - 15 m/min |
| Control System | Siemens or OEM |
CFRT UD Prepreg Tape Line
Continuous melt-impregnation line producing unidirectional thermoplastic prepreg tape in a single pass, with selectable spindle count and resin system.
| Parameter | Value |
|---|---|
| Spindle Number | 72 / 96 / 192 / 384 / 600 / 700 |
| Applicable Resins | PEEK / PA / PC / PPS / PEI / PA6 / PP |
| Product Width | 300 - 1800 mm |
| Applicable Materials | Carbon / Glass / Aramid fiber |
| Product Thickness | 0.15 - 0.5 mm |
| Line Speed | 5 - 20 m/min |
| Heating Zone Length | 600 - 3000 mm |
| Control System | Siemens or OEM |
Manufacturing Process Flow
Two lines run in sequence. Line 1 produces continuous UD prepreg tape; that tape feeds Line 2 directly to form panels - with no intermediate slitting or re-winding, so fiber orientation is preserved end to end.
Tape line output width 300 - 1800 mm | Tape thickness 0.15 - 0.5 mm | Panel width <= 3200 mm | Panel thickness 8 - 60 mm
Quality Validation
Mechanical testing verifies that Zloonex self-developed ultra-thin continuous laminates consistently outperform high-end imported alternatives.