The Organosheet process

At EMI, we develop innovative solutions to meet the challenges of producing lightweight, high-performance structural components.

🎯 The challenge:
To enable our client to thermoform and overmould two materials onto a thermoplastic composite sheet in a single operation, with a high level of repeatability thanks to a fully automated process, in order to replace a safety component (foot A) previously made of steel.

🔧 Our solution: a comprehensive and controlled organosheet process

✅ Thermoforming and overmoulding in a single injection cycle
✅ Dual-material tooling developed and optimised in-house
✅ Integration of an infrared oven for composite shaping
✅ 6-axis robot for handling and precision operations
✅ Cooling table 
✅ 700-tonne press adapted to the mechanical requirements
✅ Glass fibre-reinforced thermoplastic composite material

This process demonstrates our ability to integrate thermoforming, injection moulding and robotic automation to produce high value-added technical parts 💪

📽️ See this process in action in the video here👇