Covestro Expands CFRTP Portfolio with New Tape Line and Hybrid Injection Molding

Covestro, based in Pittsburgh, Pennsylvania, is advancing its continuous fiber‑reinforced thermoplastic (CFRTP) composites to meet evolving market demands and growing customer needs.

The Maezio line of CFRTPs utilizes continuous carbon fibers embedded in thermoplastic matrices such as polycarbonates. A state‑of‑the‑art tape line has been commissioned at the company’s Leverkusen, Germany laboratory, enabling rapid development of new fiber‑resin combinations. Successful prototypes will be scaled and commercialized at the production facility in Markt Bibart, South Germany.

“We’re seeing strong market demand for thinner, lighter, and visually appealing products where thermoplastic composites like Maezio excel,” says Lisa Ketelsen, head of Covestro’s thermoplastic composite business. “To support a broader application range, we need a wider portfolio with varied matrix materials and properties. The new tape line, combined with our mass‑production lines, will allow us to iterate quickly and scale production in line with customer demand.”

One product under development is a TPU‑based CFRTP that offers exceptional chemical resistance and flexibility across a wide temperature spectrum. This material is especially attractive to the footwear and sports‑equipment sectors, where strength and versatility are paramount.

Simultaneously, Covestro has commissioned hybrid injection‑molding machines at its CFRTP sites in Germany and China. These machines merge thermo‑forming of semi‑finished composite parts with in‑mold injection molding, delivering a fully automated, one‑step process that reduces cycle times and boosts productivity for mass‑produced composite components. Collaborating with industry partners such as Krauss Maffei and Engel, Covestro provides comprehensive support throughout the product‑development lifecycle.