Lightweight Construction, Design & Performance with Thermoplastic Composites
The automotive industry is undergoing a profound transformation: lightweight construction, e-mobility, and sustainability are shaping the future of vehicle development. This requires materials that are lightweight, strong, temperature-resistant, and versatile in processing. To meet these demands, innovative materials are needed that are lightweight, strong, corrosion-resistant, and heat- and flame-resistant, while remaining flexible in processing.
HELD offers tailored solutions for the development of modern vehicle components made from thermoplastic composites. These high-tech materials enable a new generation of components that optimally combine lightweight construction, design, and performance.
The key advantage lies in lightweight construction: significant weight reduction lowers energy consumption. This is an important factor for the efficiency and range of modern vehicles, particularly in the field of e-mobility. At the same time, the materials used offer outstanding corrosion resistance, surpassing metal parts and providing durability and maintenance-free operation.
In terms of safety and stability, HELD composites also excel. Their high strength ensures exceptional resistance to impact and compressive loads. The integration of inherently flame-retardant fabrics with meta-aramid chemistry provides effective fire protection.
HELD technology thus creates a forward-looking foundation for innovative vehicle components that meet the highest demands in lightweight construction, design, and performance, from sample production to series production.
Multiple Quality Layers in a Single Process
HELD double belt presses are the core of modern composite and laminate production. Fiber-reinforced semi-finished products, technical films, and laminates are essential in vehicles, enabling functionality, safety, and design. In the continuous pressing process, laminating, compacting, consolidating, and smoothing are combined in a single precise pass. The result: perfect surfaces, homogeneous structures, and reproducible material properties — from ultra-lightweight composite structures to decorative interior components for the automotive sector. In vehicle manufacturing, the focus is on crash safety, weight reduction (CO₂ reduction), and suitability for series production.
Typical components include:
Bodywork: Components for doors, e.g., inner shells and bumper parts (crash structures made from carbon fiber-reinforced thermoplastics).
Decor layers: For example, wood-effect decor, decorative panels, or high-quality decor laminates.
Interior components: Lightweight composite panels or materials for instrument panels (carrier plates), seat shells, backrests, armrests, and door panels.
Structural and safety components: Cross members, longitudinal beams made from CFK/GFK composites, battery trays and housings for e-vehicles, crash absorber elements.
Electrically conductive layers: Copper laminates or laminated metallic layers, e.g., for shielding or conductive surfaces.
Which one is the ideal production technology for your application?
In our exclusive white paper series, we compare the performance of different pressing processes such as calendering, static and continuous pressing with our isobaric continuous pressing process for different materials such as fuel cell components, composites, etc..
In addition to specialty materials, standard thermoplastics such as polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC) also play a major role in industrial processing. These materials are versatile and cost-effective to manufacture.
Thermoplastics are processed using methods such as extrusion or thermoforming — proven technologies suitable for both series production and custom components.
A particular highlight in the field of thermoplastic materials is Tepex®, a fiber-reinforced composite with a thermoplastic matrix. It combines low weight with high strength and stiffness, making it ideal for structural and design-relevant components in the automotive interior, such as trim panels, seat shells, consoles, or reinforcement elements. Tepex materials can be efficiently combined with other thermoplastics through hybrid and overmolding processes. This enables the production of durable, shape-stable, and visually high-quality components that meet the increasing demands for lightweight construction, safety, and sustainability.
Composites
A particular focus is on glass fiber-reinforced plastics, carbon fibers, and plastics with carbon fabric. These materials offer an outstanding strength-to-weight ratio. In combination with processes such as layer lamination, highly durable components are produced for demanding applications.
Prepregs and organo sheets are key semi-finished products for lightweight and composite applications.
HELD – Your Partner for Innovative Composite Materials
Whether composites, engineering plastics, or high-performance polymers: HELD offers a broad range of solutions. With our expertise in thermoplastics, fiber-reinforced plastics, and innovative laminating processes, we develop materials that set new standards. Request a sample production now - without obligation.