Faster ramp-up, lower cycle times Composite mould system revolutionises thermoset temperature control

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At JEC World 2026 in Paris, Cannon unveils Nexus, a composite mould system that redefines thermoset temperature control. By integrating heating elements directly into the mould structure, the technology delivers temperature ramp-ups of up to 30°C per minute, cuts energy consumption by more than 70 percent and boosts efficiency by 25 percent compared to conventional fluid-based systems.

At JEC World 2026 (Paris Nord Villepinte, March 10 to 12), Cannon introduces the all-new Nexus system, comprised of a composite mould, thermoregulation system and the associated controls. This new method for regulating mould temperatures allows for a 25 percent increase in efficiency compared to standard mould heating practices. In addition, the system opens up new optimization scenarios previously unavailable while reducing cycle times, with the aim of increasing part quality and potentially cutting raw material usage. Initially aimed at manufacturers using PU RIM (Reaction Injection Moulding), the Nexus system is also applicable to many processes that involve thermoset materials.

Nexus technology uses the physical properties of composites not only as structural reinforcement, but as heating elements integrated into the mold itself. This allows for extremely fast temperature ramp-ups, up to 30°C per minute, as well as much more precise localized temperature control compared to fluid-based systems. Within the mould, this makes it possible to create differentiated thermal areas, separated by gradients less than a few millimeters. This feature is particularly useful in processes where the material’s chemical kinetics have to be carefully modulated. The nature of composites also offers the possibility of designing the mold with “tailor-made” properties, calibrating the heating rate, transverse conductivity or heat distribution according to the requirements of the part to be produced.

Developing the Nexus system required over ten years of experimentation, beginning in 2015 with the aim of improving efficiency for RIM and HP-RTM processes. As literature on using composites as heating elements was limited, Cannon conducted a series of internal electrical and thermal tests to fully understand their behavior. Based on the data collected, a mathematical model was built to simulate an operational composite mold with integrated heating.

“In thermoset moulding, heat management is a crucial factor in achieving consistent quality, competitive cycle times and energy-sustainable processes,” said Andrea Castelnovo, Technology and R&D Manager at Cannon Tipos. “Traditional technologies, based on metal tools and thermal fluids, have reached a physiological limit. Even when optimized, they rarely exceed 75 percent energy efficiency and impose thermal inertia that affects the entire production process. These considerations led to the creation of Nexus, offering a completely new approach to mould temperature control, based on the intrinsic properties of the composite materials. The goal was simple in theory but revolutionary in practice: to heat only what is needed, in the shortest possible time, thus minimizing energy waste and dispersion.”

Even before the first Nexus prototype was built, composite plates had been produced using the same principle. These allowed Cannon to compare simulation and reality, optimize the heater layout, and define the correct material sequence. The next step was to build a demonstration mould designed to replicate the operating conditions of a RIM process for polyurethane foams. Field tests then confirmed the theoretical results: the quality of the parts produced was equivalent to that obtained by more established technologies, while energy consumption was reduced by over 70 percent. Furthermore, the time needed to bring the mold temperature up was drastically reduced, from about one hour to around 8 minutes.

Nexus is aligned with Sustainable Development Goal 12 for Responsible Consumption and Production, giving manufacturers the ability to precisely regulate temperatures in order to maximize material expansion and reaction performance. It reduces raw material usage and cycle times, while eliminating hazardous thermal fluids from the process; this, in turn, simplifies the plant’s overall energy infrastructure by removing the need for complicated heating and piping.

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