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Thermoplastic Carbon
Advanced Thermoplastic Composite Manufacturing Technology
ASTRO's Thermoplastic Carbon technology combines continuous carbon fiber reinforcement with thermoplastic resin to enable high-strength, impact-resistant, lightweight structures and highly automated frame manufacturing.
Thermoplastic Carbon Technology Advantages
Engineered for Lightweight Performance, Efficient Production, and Design Flexibility.
Designed for Sustainability
Tougher & Better Impact Resistant
Comfortable & Stable Ride
Consistent Quality
Lightweight Structure
Optimized fiber orientation and structural design deliver lightweight performance with high stiffness.
Automated Production
High-pressure forming and automated processes enable consistent and efficient frame production.
Target production cycle: approximately 15 minutes per frame
High Impact Resistance
Thermoplastic composite structures provide high impact resistance and durability for demanding applications.
Recyclability Potential
Thermoplastic materials can be reheated and reprocessed, supporting material recovery and circular manufacturing.
Thermoplastic Carbon Manufacturing Process
From Carbon Fiber Prepreg to Recyclable Material Recovery
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01 — Prepreg Preparation
Carbon fibers are impregnated with thermoplastic resin to create carbon fiber reinforced thermoplastic prepreg sheets. -
02 — Cutting & Layup
Prepreg sheets are cut and layered according to the required fiber orientation, thickness, and structural design.
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03 — High-Pressure Forming
The layered material is heated and formed under controlled high temperature and pressure to create the required structural geometry. -
04 — Thermoplastic Joining
Thermoplastic-specific joining processes are applied to integrate structural components and achieve consistent joint performance.
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05 — Material Recovery
Excess thermoplastic material generated during the forming process is collected and processed for material recovery. -
06 — Reprocessing
Recovered material can be processed into thermoplastic pellets for use in new components.
Engineered for Scalable Production
ASTRO developed its Thermoplastic Carbon technology in Taiwan, combining material engineering, frame design, process development, automation, and production validation to support scalable manufacturing.
Material
Engineering
Carbon fiber and thermoplastic material development
Structural
Engineering
Frame geometry and load-oriented structural design
Process
Engineering
Thermoforming, joining, finishing and process optimization
Production
Automation
Automated manufacturing for consistent quality and scalable production
Material Recovery & Circular Manufacturing
Thermoplastic materials can be reheated and reprocessed, enabling material recovery from production scrap and supporting more circular manufacturing practices.
Thermoplastic Carbon Applications
- E-MTB Frames
- Gravel Frames
- Urban E-Bike Frames
- Future Mobility Platforms
- Other Industrial Uses
Develop Your Next Thermoplastic Frame
Talk with ASTRO's engineering team about thermoplastic frame development, material selection, structural design, prototyping, and scalable production.