Composite injection overmoulding

Injection moulding is one of the most common fibre-reinforced composite processing methods suitable for mass production of thermoplastic components, offering good levels of dimensional stability and part consistency. Injection moulding accounts for approximately a third of all fibre-reinforced composites produced. Recent advances in thermoplastic injection moulding have enabled manufacturers to include continuous fibre reinforcements to enhance the local mechanical performance of structural and semi-structural parts. This process, often referred to as composite injection overmoulding, is based on the injection of a thermoplastic resin (which may include short reinforcing fibres) over a polymer composite laminate, facilitating the production of fine geometric details not easily amenable through other manufacturing routes. The possibility of selective reinforcement within components to meet specific service requirements is another advantage of this technique and is increasingly being explored for the manufacture of aerospace and automotive components, among other applications. The focus of this chapter is on the practicalities of this process, providing manufacturers, part designers, and researchers with an overview of some of the most common challenges faced when producing structures with hybrid fibre architectures.