Prepreg, Tow Preg & Spreading Technology

Engineering the Future of Composites

Cygnet Texkimp is a global leader in prepreg and tow preg processing technology, trusted by manufacturers in aerospace, automotive, construction, and advanced composites  to deliver precision, performance, and scalability.

Already one of the world’s largest suppliers of thermoset prepreg machinery to the aerospace sector , we are redefining what’s possible in composite manufacturing with the world’s first commercially available, high-volume thermoplastic prepreg processing lines.

Our technology empowers manufacturers to produce stronger, lighter, and more sustainable materials – unlocking the full potential of composite performance while achieving efficiency, repeatability, and commercial viability at scale.

From aerospace-grade thermoset systems to high-volume thermoplastic lines, and from precision tow impregnation to advanced fibre spreading, Cygnet Texkimp is shaping the future of composite manufacturing.

Our technologies bring together British engineering excellence, decades of fibre-handling expertise, and continuous innovation, enabling customers to produce advanced materials with greater speed, precision, and sustainability – all from a single trusted partner.

Most composite materials used today are based on thermoset resin systems, where a precisely metered resin is applied to a reinforcing fibre — such as carbon, glass, or aramid — before being chemically cured to create a continuous prepreg sheet. This sheet can be moulded, laminated, or slit into tapes for automated tape laying, filament winding, or fibre placement applications.

Cygnet Texkimp’s thermoset prepreg lines are designed for exceptional accuracy and control, achieving the lowest and most uniform coat weights in the market. Working in conjunction with our high-precision filming and coating systems, they produce light, thin, and consistently strong prepregs that meet the demanding standards of aerospace and other high-performance industries.

Key benefits:

  • Precision resin control for consistent quality and strength
  • High-speed processing for greater production efficiency
  • Uniform resin distribution and optimal fibre wet-out
  • Configurable widths and coat weights for tailored applications

Thermoplastic prepregs are increasingly becoming the material of choice for next-generation composite applications — offering a versatile, efficient, and sustainable alternative to traditional thermosets.

Unlike thermoset prepregs, thermoplastic prepregs are easier to handle, faster to process, and fully recyclable, while providing outstanding impact resistance, chemical durability, and toughness. These properties make them ideal for automotive, construction, industrial, and aerospace markets seeking lightweighting and circular manufacturing solutions.

Cygnet Texkimp’s Direct Melt Impregnation Thermoplastic Line represents a step change in composite production. Believed to be the world’s first commercially available thermoplastic prepreg line capable of using standard polymers — from polypropylene to PEEK — in pellet form, it enables the industrial-scale manufacture of high-grade thermoplastic tapes with exceptional consistency and performance.

By using polymer pellets directly, this system simplifies and shortens the prepreg manufacturing process, reducing cost and complexity without compromising quality. The machine’s compact footprint allows it to fit easily within standard production facilities and be operated without specialist expertise — making thermoplastic prepreg manufacturing truly accessible for the first time.

Key advantages:

  • Compatible with standard polymers (e.g. PP, PEI, PPS, PEEK)
  • Simplified, direct melt impregnation process
  • Compact and easy to integrate into existing facilities
  • Ideal for high-volume, high-quality thermoplastic tape production
  • Enables faster cycle times and lower environmental impact

Our Tow Preg systems are designed to produce precisely impregnated filament bundles — or tows — for use in a range of downstream composite processes.

The process involves applying a resin or polymer uniformly to a single continuous tow (typically 12k, 24k, or 50k fibre count) to achieve a predetermined resin ratio, ensuring consistent quality and predictable performance.

These systems are engineered for speed, precision, and economy, delivering cost-effective, high-volume production of tow pregs suitable for filament winding, weaving, and automated fibre placement. Tow pregs can also be used as alternatives to slit tapes, ideal for creating thick-walled composite parts such as pressure vessels for automotive, aerospace, and marine applications.

Highlights:

  • Uniform resin impregnation for consistent filament quality
  • High-speed production for commercial-scale output
  • Compatibility with a wide range of fibre and resin systems
  • Ideal for use in high-pressure, structural composite applications

 

Cygnet Texkimp’s spreading systems are designed to transform a continuous multifilament fibre — such as carbon, glass, or aramid — into a flat, uniform sheet of individual tows. This sheet can then be impregnated with resin or adhesive to form a continuous prepreg material.

Our spreading machines draw on decades of process expertise in fibre handling and tension control, ensuring that each fibre is evenly distributed without compromising its integrity or alignment. Maintaining the stability of the spread sheet is a critical challenge — one our systems overcome through advanced control and precision engineering.

These machines are used primarily for UD (unidirectional) fibre processing in both thermoplastic and thermoset prepreg lines, providing the foundation for high-quality composite tape and sheet production.

Benefits:

  • Consistent fibre spreading for uniform resin impregnation
  • Enhanced fibre surface area for improved bonding strength
  • Stable sheet formation across high-speed production lines
  • Suitable for thermoset and thermoplastic UD applications

 

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