The Nexus composite mold heating system developed by Cannon is designed to reduce energy consumption by up to 70% compared to standard heating practices and to shorten mold heat-up time by around 80%. The solution, comprising a composite mold, thermoregulation system and associated controls, will be presented at JEC World 2026 in Paris (Paris Nord Villepinte, March 10–12). According to the manufacturer, this new method of mold temperature control enables a 25% increase in process efficiency compared to typical mold heating systems, while opening up new optimization options by reducing cycle times, with the aim of improving part quality and potentially lowering raw material usage. The Nexus system is initially targeted at manufacturers using PU RIM (Reaction Injection Molding) technology, but it is also applicable to many other processes involving thermoset resins.
Composite as an integral heating element of the mold
The Nexus technology uses the physical properties of composite materials not only as structural reinforcement but also as heating elements integrated directly into the mold. This design approach enables very fast heating, at rates of up to 30°C per minute, and much more precise local temperature control than systems based on liquid heat transfer media.
Inside the mold, it is possible to create differentiated thermal zones separated by temperature gradients of less than a few millimetres. This is particularly important in processes where the chemical reaction kinetics of the material must be precisely modulated. The use of composites also makes it possible to design a mold with tailor-made properties, with calibrated heating rate, transverse conductivity and heat distribution according to the requirements of the specific part.
A new approach to heat management in thermoset processes
"In thermoset molding, 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% 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 mold temperature control, based on the intrinsic properties of composite materials. The goal was simple in theory but revolutionary in practice, namely to heat only what is necessary, in the shortest possible time, thus minimizing energy waste and dispersion."
Ten years of development work on the Nexus system
Development of the Nexus system spanned more than ten years and began in 2015 with the aim of improving the efficiency of RIM and HP-RTM processes. Due to the limited amount of literature on the use of composites as heating elements, Cannon carried out a series of internal electrical and thermal tests to fully understand their behaviour. Based on the collected data, a mathematical model was created to simulate the operation of a composite mold with integrated heating elements.
Before the first Nexus mold prototype was built, composite plates operating on the same principle were produced. This made it possible to compare the simulation results with actual system behaviour, optimize the layout of the heating elements and define the correct material sequence. The next step was to build a demonstration mold designed to replicate the operating conditions of a RIM process for polyurethane foams.
Field tests under industrial conditions confirmed the theoretical findings. The quality of parts produced in the Nexus mold proved equivalent to that of parts manufactured using more established technologies, while energy consumption was reduced by more than 70%. In addition, the time required to reach the target mold temperature was significantly reduced, from about one hour to around 8 minutes.
Energy efficiency and alignment with sustainable development goals
The Nexus system is aligned with Sustainable Development Goal 12 "Responsible consumption and production". For manufacturers, this means the ability to control temperature very precisely in order to maximise material expansion and the course of chemical reactions. The solution helps to reduce raw material usage and shorten cycle times, while eliminating hazardous thermal fluids from the process. As a result, the plant's energy infrastructure is simplified, since there is no need for complex heating systems and extensive piping networks.
At JEC World 2026, Cannon will be present at booth 5M72, where it will showcase the capabilities of the Nexus system in applications involving thermoset resins, in particular in PU RIM processes.
Nexus composite mold with integrated heating elements for precise and energy-efficient temperature control (Photo: The Cannon Group)
