Texonic

Texonic's NC-Ply™ is an advanced reinforcement solution, a three-dimensional textile architecture designed to eliminate fiber crimp. By keeping the reinforcement fibers straight in the X and Y planes, NC-Ply™ maximizes the mechanical performance of the composite. Its structure is optimized for infusion or vacuum-assisted manufacturing processes (VARTM), providing channels for unparalleled resin flow in all three dimensions, which allows for complete and rapid wet-out. This results in very high fiber volume fractions, up to 75%, comparable to those achieved with prepregs. The presence of reinforcements in the Z-direction significantly improves interlaminar performance. This technology allows for lighter structures while being easy to work with due to its high conformability. The NC-Ply™ range is available in carbon, glass, basalt, S2 glass, or hybrid forms, with areal weights up to 150 oz/yd² in glass and 67 oz/yd² in carbon, and can be used in closed molds, wet processes, or with prepregs.

Texonic's unidirectional fabrics are the result of 30 years of development aimed at optimizing composite performance. In these reinforcements, the majority of fibers are oriented in a single direction, which maximizes stiffness and strength along that axis. This construction is ideal for applications where loads are predictable and directional. Texonic ensures perfect fiber alignment for a flawless visual appearance and reliable mechanical performance. The products are designed for excellent handling stability, clean pre-cutting, and optimal wet-out, regardless of the areal weight. This ease of processing translates into production efficiency gains. The range of unidirectional reinforcements is extensive, with areal weights from 2.6 oz/yd² to 44 oz/yd², and is available in a wide variety of materials, including carbon, Kevlar, glass, and hybrids. Typical applications include surfboards, skis, boat hulls, masts, drones, and infrastructure rehabilitation.

Uniflex™ and Instaform™ are proprietary Texonic technologies designed to improve the handling and performance of composite reinforcements. The main objective is to maintain perfect fiber alignment and positioning, which is crucial for both mechanical performance and the final appearance of parts where the reinforcement remains visible. These technologies optimize the flexibility-to-stiffness ratio of the fabrics, making them easier to handle, cut, and drape into molds. Texonic uses this system to produce superior quality unidirectionals and to stabilize fabric architectures that naturally tend to misalign. This is particularly useful for ultra-lightweight reinforcements, which can be difficult to handle without distortion. In summary, Uniflex™ and Instaform™ contribute to more efficient processing and a higher quality finished product by ensuring the structural and aesthetic integrity of the reinforcement throughout the manufacturing process.

The Smart Hybrid™ is an innovative concept from Texonic that replaces the traditional approach of layering different materials. Instead of adding separate layers to achieve complementary properties, the Smart Hybrid™ integrates different fibers directly within the same fabric. This means that a single layer of reinforcement can have zones with different compositions, allowing for precise tailoring of performance where it is needed. For example, one area can be reinforced with carbon for stiffness, while another can use aramid for impact resistance. This method allows for the optimization of the composite structure by placing the right material in the right place, without the added thickness or extra manufacturing steps associated with adding reinforcement patches. The result is a lighter, higher-performing, and potentially more cost-effective part to produce. This concept illustrates Texonic's ability to create on-demand architectures for specific performance needs.

Texonic stands out for its ability to produce true custom three-dimensional (3D) textile structures. Unlike stacking 2D fabrics, these structures integrate reinforcements in all three dimensions (X, Y, and Z) during a single manufacturing process. The addition of fibers in the Z-axis (through the thickness) is particularly crucial for significantly increasing the interlaminar performance and delamination resistance of thick composite structures. This technology enables the creation of very thick preforms with superior structural integrity. Texonic offers precise control over the orientation and position of fibers in all three dimensions, which is essential for optimizing the mechanical properties of complex, thick-section parts. This advanced manufacturing capability places Texonic among a select few companies worldwide capable of providing such solutions, meeting the needs of the most demanding applications where through-thickness performance is critical.

With over 30 years of experience in this field, Texonic is a pioneer in the development of reinforcements for thermoplastic composites. The company specializes in weaving commingled fibers, which are intimate blends of reinforcement fibers and thermoplastic matrix fibers. This approach ensures a homogeneous distribution of the matrix within the reinforcement, which is essential for obtaining high-quality parts. Parts are manufactured by simultaneously applying heat to melt the thermoplastic matrix and pressure to consolidate the part. Texonic works with a variety of combinations, such as Carbon/PEEK, Carbon/PEI, Carbon/PPS, Glass/Polypropylene, and Carbon/Polyamide. These materials offer advantages like faster cycle times, better recyclability, and increased toughness compared to many thermoset composites. Texonic's expertise in this sector allows it to provide ready-to-thermoform reinforcement solutions for demanding applications.

Texonic's ability to develop custom solutions is a cornerstone of its reputation. The company does not just provide a product catalog; it engages in a partnership with its clients to design the optimal textile reinforcement. This collaborative process involves a team of experts in composites, textiles, structures, and manufacturing methods. By working with the client, Texonic can identify unique challenges related to performance, weight, cost, or the manufacturing process. The solutions can range from adapting an existing architecture to creating an entirely new product, such as a Smart Hybrid™ where the material composition varies locally. This approach allows for the creation of reinforcements that are not only high-performing but also easier to implement, simplifying clients' lives and improving efficiency. This flexibility is a key strength, enabling a precise response to needs, whether for specific architectures or a unique visual appearance.