Rethinking Lightweight Construction: At K 2025, ENGEL presents a series-ready solution for highly efficient lightweight design with reduced material usage

Integrated technology for hollow, reinforced parts

ENGEL demonstrates a closed, continuous process that combines local reinforcement with continuous UD tapes and fluidmelt technology for forming hollow bodies. The fully automated cell operates on an ENGEL victory 180 tie-bar-less machine (1800 kN) and integrates overmoulding of tapes and the creation of a hollow structure in one step.

Compared with aluminum solutions that require multiple stages, this achieves a cycle time of around 60 s, delivering higher capacity and cost savings. The solution demonstrates that plastics, with the right engineering, can replace aluminum while offering shorter cycles, better functional integration and greater design freedom.

Materials and process

The components are made of polyamide 6 with 50% glass fibre (DOMO Chemicals). Four UD carbon fibre tapes are placed in the mould prior to injection, so the part — despite its thin walls and hollow structure — withstands high mechanical loads.

During the fluidmelt process, gas is injected to push the plastic core back into the plasticising unit, creating a hollow space. The displaced material is reused in the next cycle, reducing waste and energy consumption per part.

Lightweight construction for urban mobility – victory 1560/180

On the tie-bar-less victory 1560/180 machine, bicycle handlebars made of polyamide are produced using the ENGEL fluidmelt process. The combination with unidirectional (UD) tapes provides additional stiffness and strength. Result: weight savings, high stability and maximum design freedom.

Engineering journey of the cockpit handlebar (video)

The video shows the development journey of the cockpit handlebar — from engineering to series production.

Technical details of the production cell

Automation and process control

Production automation is handled by the ENGEL easix articulated robot — inserting inserts and UD tapes, as well as removing finished parts. All movements and process steps are coordinated via the machine’s central control unit — CC300.

Technology ready for series production and sustainability

The handlebar has passed all required approvals, complies with ISO standards and CANYON’s internal specifications, and the technology is ready for series production from 2026. The concept enables economical local production in Europe and significantly reduces the ecological footprint thanks to an improved carbon balance.

ENGEL victory 180 wide-platen – tie-bar-less machine

This machine is intended for large and complex components and moulds. The tie-bar-less design with a large, unobstructed platen area enables work with demanding moulds on a compact machine size — an advantage when integrating complex automation.

Scalability and applications

Both the combination of technologies and the production cell can be modularly adapted to different geometries and industries. This system is suitable for sports and leisure, the automotive industry and for manufacturing technical parts with hollow geometries.