Thermoplastic Sandwich

Sandwich materials are made from combining outer layers of reinforced thermoplastic organosheets together with thermoplastic foam. The organosheets are made by weaving continuous reinforcement fibres that are commingled with continuous matrix filaments. This results in hybrid fabrics, which are then stacked and consolidated on the foam.

The sandwich panels can be shaped at consolidation, or the flat panels can be shaped later. The resulting sandwich material is adhesive-free, lightweight with high mechanical properties and can be repaired or recycled, both mechanically and chemically.

The composite sandwich has the possibility of being manufactured of a single material, which makes the sandwich 100% recyclable, just like the Comfil Self-reinforced thermoplastic PET and PLA product lines.


Comfil thermoplastic sandwich materials can be made of any compatible foam-fibre-matrix combination and is typically used for composite processes where weight savings are critical like aviation, automotive, packaging and protection.

The sandwich panels can be thermoformed into shape, over-moulded and holds a very attractive weight to performance ratio. The foam core provides stiffness, compressive strength, while the outer layers provide strength, abrasion and impact resistance


Sandwich Structure


Unlike thermoset sandwich materials, Comfil thermoplastic sandwiches have the advantage of thermoforming, which has time and cost efficient benefits, as this production method can be based on high-volume semi-finished products.

Core compaction

For thermoplastic foam sandwich cores a compaction step is applicable, which enables to achieve a gradual foam density and therefore optimized load transmission.

Co-injection molding

Adding Ribs or functional elements like clips using co-injection and over-moulding techniques.