Fiber-reinforced thermoplastics have a high potential for big scale light weight process applications due to low processing times and recyclability. Further advantages are the low emissions during the manufacturing process and beneficial handling and storing properties of the semi finished materials. Thermoplastic composites are made of reinforcement fibers and a thermoplastic polymer matrix by applying two essential sub processes: (1) melting of the matrix-material and (2) impregnating the textile component with molten matrix-material. At present state of art both sub-processes are applied by using double-belt-presses, characterized by high processing temperatures and high processing forces. Therefore, a large amount of energy is needed to create the necessarily high compaction forces and temperatures with hydraulic cylinders and electric heating. Convection, infrared-radiation and the cooling (dynamic) of tempered machine parts leads to a significant dissipation of energy. Especially the process for generating the hydraulic pressure has a low level of efficiency. Therefore, in respect to economic and ecologic reasons, novel energy-efficient impregnation processes need to be investigated and developed. The represented novel impregnation process is based on ultrasonic technology. A stack of polymer film (outer layers) and a textile ply (inner layer) is formed and the energy is applied with an ultrasonic sonotrode. The efficient, fast and strongly concentrated energy application into the thermoplastic films allows the development of novel and highly flexible machine concepts. These can be used for development of small scale up to large scale production processes. The ultrasonic-technology allows a continuous impregnation of the textile component with molten matrix-material. A custom-designed prototype was developed. First material samples were produced and the technological parameters studied. A characterization of the experimental results, material samples, prototype machine and process is the focus of this paper.

Multi‐component micro‐injection molding enables the manufacturing of active elements as well as electrical contacting in situ and in a single process by using piezo active and electroconductive plastic compounds. Each compound is functionalized with filler materials according to its special demands. To this end, polypropylene (PP) with an electromechanical active filler based on piezoceramic powder (PZT: Lead zirconate titanate) for sensor functionality as well as PP with electroconductive properties based on carbon nanotubes (CNT) and carbon black (CB) for electrical contacting are investigated. Therefore, different compound compositions are analyzed with regard to their mechanical and electrical properties as well as their mechanical compatibility. For the analyses, micro injection molded samples of the different compounds are used. Furthermore, investigations on composite strength are conducted by measuring interlaminar shear strength between the functionalized compounds. Based on the material characterization, a simulation of the thermomechanical behavior is done and the process‐related residual stresses are analyzed. To achieve the prerequisites for fabricating sensor modules in mass production, the functionalized compounds should be processed by means of the two‐component micro‐injection molding technology. According to this, the objective target is a large‐scale integration of these piezo modules into multifunctional lightweight structures. Therefore, the modules are combined with electrically functionalized textile substrates creating semi‐finished products with sensor functionalities. The mechanical and electrical connections are created by ultrasonic welding. Applying this technology requires a manufacturing study with varying process parameters of joining force, amplitude and welding time with the aim of achieving minimal electrical contact resistance.