Composite materials increasingly are being used by automakers to reduce vehicle weight and improve fuel economy.

However, because of the expense and complexity of many composites, these materials have been relegated largely to luxury-class vehicles.

Composite part made by the PulPress method from a structural foam core woven around with fibers.Now, a German specialty chemical and performance materials maker has developed a process to mass produce complex molded parts.

The PulPress method developed by Evonik Industries AG combines two traditional production techniques, as the name suggests: compression molding and pultrusion. Combined, they make automated, continuous production of composite parts possible, the company says.

The raw material used in the process is a structural foam made by Evonik called Rohacell that acts as the core. It’s a light, yet rigid and temperature-resistant foam that retains its shape. Fibers are then woven around the core before it is impregnated with resin.

The complete system is then compressed into the desired shape at high temperature and pressure. The method allows manufacturers to produce complex geometries and integrate recessed areas for threaded components or other fixtures, says Evonik.

The PulPress method is said to reduce manufacturing costs of composite parts by up to 60% compared to composite parts made using conventional processes such as resin injection.

In addition to automotive applications, the process can be used to make composite parts for aircraft, sports equipment and other products requiring lightweight yet rigid materials.