Today's KNOWLEDGE Share
Chopped UD (Forged Flakes) is one of the most flexible composite formats we work with at COREX where we are combining continuous-fiber performance with molded-part design freedom.
Chopped UD is produced by cutting unidirectional thermoplastic tape into controlled flakes (typically 5–25 mm) and compression-molding them into near-net-shape parts. This creates a material architecture that’s both high-performance and highly designable.
What makes it special:
> Quasi-isotropic properties from the random orientation of the flakes
> Tunable anisotropy by orienting flakes in a preferred flow direction during molding
> Premium aesthetics: smooth, uniform surfaces suitable for visible parts
> Long fibers (10–25 mm), far longer and stronger than injection-molding compounds
> High fiber volume fraction (45–55%) for structural stiffness and impact strength
> Variable thickness within the same part, thin skins + reinforced zones molded in one cycle
> Integrated features, ribs, frames, bosses, and fixtures formed directly in the mold, eliminating secondary overmolding
> Fine geometric detail: sharp corners, inserts, and complex 3D transitions
> Circularity: flakes can be produced from reclaimed UD prepreg offcuts
COREX Materials is leveraging this platform across mobility, electronics, aerospace interiors, sports, and protection, where weight, durability, and manufacturing precision matter.
Chopped UD is not a downgraded material. It’s a programmable composite architecture combining our three pillars of Performance, Agility and Circularity.
source : Pierre Coat
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