KNITU-KAI is developing a technology for mass molding of thermoplastics with a moldable filler.
A team of engineers at the A.N. Tupolev Kazan National Research Technical University — KAI — received a grant of 5 million rubles to create a new technology for molding thermoplastics with a moldable foamed filler.
The project is being implemented as part of the national project "New Materials and Chemistry" and is financed under the "Start-1" program of the Foundation for Assistance to Innovations (FSI).
The university played a key role in implementing the project, supporting the student idea at the initial stage. The ecosystem of KAI’s Advanced Engineering School provided technological equipment, materials, digital expertise, support for R&D, research methodologies and assistance in formalizing results of intellectual activity (RIA), and also ensured integration with Tatarstan’s industry.
Experts note that the new technology could find applications in the production of unmanned aerial systems, aviation components, automotive parts, housings for consumer devices and products for the defense industry. The total market potential in Russia is estimated at approximately 30 billion rubles with an average annual growth of around 9%.
KAI engineers are developing the molding technology for thermoplastics with a moldable foamed filler for the mass production of lightweight products with an internal load-bearing frame. As a pilot application they have chosen sports equipment — padel tennis rackets, whose popularity in Russia is growing.
According to the developers’ estimates, imports account for 97% of the racket market, which is worth 100–150 million rubles per year, and the segment’s average annual growth is about 60%. The new products promise to be comparable to foreign counterparts in elasticity, but 2–3 times cheaper, making them accessible to professional athletes, sports schools and equipment rental companies.
The head of the special educational space of KAI’s Advanced Engineering School "Technological Modeling," Evgeny Puzyretsky, explained that the new technology removes the limitations of the team’s previous project, implemented in 2024 with a "Student Startup" grant. At that time composite oars for professional rowing were developed, but mass production encountered technological barriers.
He added that the "APEX Composite" technology, developed jointly with KAI, combines the advantages of traditional thermoplastic molding and the methods of vacuum infusion, contact molding and the use of prepregs, providing an optimal ratio of mass to strength in mass production.
At the next stage of the project it is planned to develop a method for manufacturing the filler and to register two utility models of molds, which will create prerequisites for scalable serial production of the products.
Photo: press service of KNRTU-KAI
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KNRTU-KAI creates a technology for mass molding of thermoplastics with a moldable filler
The project is being implemented as part of the national project "New Materials and Chemistry". 12:54 23.12.2025 Zainsk-Inform - Zainsk
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KNRTU-KAI creates a technology for mass molding of thermoplastics with a moldable filler
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