The FuturePlas project is now successfully completed, having run from November 2007 until July 2009.  Its aim was to reduce the weight and improve the performance of plastic components by developing the next generation of lightweight, high strength, recyclable polymers. The project involved 8 UK partners representing the entire supply chain and had a total value of £700,000.
The project has produced Self Reinforced Plastic (SRP) variants suitable for more detailed moulding than is currently possible and in a variety of previously untapped materials. SRP materials offer stiff, lightweight, impact resistant properties and, because they are a single polymer composite, easy recyclability. Building on the current commercially available Self Reinforced Polypropylene (SRPP) Futureplas has analysed a range of SRP’s such as Polyethylene terephthalate (PET), Nylon (PA) and Polyethylene (PE) and broadened the processing possibilities to include flow moulding and various sheet and fabric cross-over moulding technologies.

Hot-compacted PE (HCPE) has been particularly promising and case study parts have been manufactured and tested in this material, meeting typical automotive specifications for existing steel brackets used in load bearing applications. Compression moulded parts from PET and PE fabrics and pellets have also been made which exhibit the desired flow characteristics of the matrix phase allowing the formation of detailed features in mouldings such as bosses and ribs.Injection moulding of SRP parts was the most ambitious aim of Futureplas  – to mould at high pressure and yet retain fibre properties – and small-scale injection moulded samples have been manufactured which can flow into complex shapes and yet remain reinforced with short fibres. Safety helmets have also been manufactured and tested using over-moulding technology and there is a significant improvement in both energy absorption and impact resistance.


This project was co-funded by the Technology Strategy Board's Collaborative Research and Development programme. The Technology Strategy Board is an executive body established by the Government to drive innovation. It promotes and invests in research, development and the exploitation of science, technology and new ideas for the benefit of business - increasing sustainable economic growth. Visit  www.innovateuk.org.