Ensinger has expanded its high-performance materials portfolio with a new line of engineering particle foams designed for demanding applications across aerospace, electronics, medical technology and industrial sectors. Built on thermoplastics such as polycarbonate (PC), polyethersulfone (PESU) and polyether ether ketone (PEEK) the foams combine the structural benefits of traditional particle foams with the enhanced mechanical and thermal properties of engineering polymers.

Produced through an energy-efficient manufacturing process, the foams feature a fine, homogeneous cell structure with density and material properties that can be tailored to customer requirements. Depending on the base polymer, the materials can withstand temperatures up to 300°C and exhibit strong resistance to oils, greases, cleaning agents and solvents. These properties make them suitable for lightweight structural components, impact-resistant parts and applications requiring long-term durability in chemically aggressive environments.

The product line is currently in the pilot phase, with beads in multiple densities and foam sheets available in sample sizes for development and testing. Ensinger also offers engineering support and the ability to develop custom-molded parts for project-specific applications.

For more information, visit ensingerplastics.com/en/particle-foam.

A global research collaboration has introduced a double-sided large-scale additive manufacturing (LSAM) tool designed to advance tidal turbine blade production. The project, led by Thermwood Corporation in partnership with Purdue University, the University of Sheffield and the University of Oxford, was demonstrated at JEC Composites 2025, where Thermwood’s LSAM 510 system printed both sides of a 2-meter tool using carbon fiber reinforced polycarbonate. The approach reduces tooling fabrication time from months to weeks.

Purdue University’s ADDITIVE3D simulation platform was used to virtually model the printing and post-processing stages, including temperature evolution, heat treatment and anisotropic shape compensation. This predictive capability supports improved process reliability and dimensional accuracy for large composite tooling.

Following printing, the University of Sheffield’s Advanced Manufacturing Research Centre performed precision machining to integrate sensor channels, blade root locator mounts and resin flow features. The resulting tool enables single-shot infusion of carbon fiber reinforcement around a polycarbonate core and stainless-steel root, creating a lightweight blade structure with enhanced efficiency.

The blade incorporates embedded sensing technologies — fiber optics, strain gauges, thermocouples and accelerometers — to support real-time monitoring during manufacturing and operation. Testing will continue at the University of Edinburgh’s FastBlade facility before upcoming sea trials, providing data on performance, durability and environmental loading. The project demonstrates how additive manufacturing innovations can accelerate the development of renewable tidal energy systems.

For more information, visit thermwood.com.