Innovative process of overmolding composite struts

SOMOCAP and EPSILON COMPOSITE present an innovative patented overmolding process of a composite thermoplastic end fitting on a hollow pultruded carbon composite profile which combines two processes known for their reliability and their production rate: pultrusion and injection.

The direct over-injection of high-performance thermoplastic composite ends on an ultra-stiff pultruded tube, specifically configured and treated, is capable to meet extreme requirements. It also gives the designer the possibility to consider complex geometric shapes for the junction elements in order to integrate a maximum of functions in a single operation.

This technology suitable for medium and large-scale production is a perfect solution to replace traditional solutions such as structural bonding or riveting, because it provides a high reliability, reproducibility and competitiveness. Thermoplastics also allows recycling at the end of life of the product.

After a successful aeronautical qualification for the Airbus A350 program – more than 15,000 secondary structure connecting rods fitted to the Airbus A350s with 0 delivery delays and 0 complaints – the process enabled in 2023 new qualifications from world leader in robotics and agricultural machinery.

These qualifications demonstrate the potential of this structural assembly process as an alternative to bonding for a multitude of sectors of activity.