CANNON has unveiled NEXUS, a next-generation mold heating system designed to dramatically improve energy efficiency and production performance in thermoset molding applications. The system, presented at JEC World 2026 in Paris, integrates a composite mold structure, advanced thermoregulation technology, and dedicated control systems into a unified solution.
Compared with conventional mold heating methods, NEXUS delivers approximately 25% higher operational efficiency. More significantly, it reduces mold heating energy consumption by more than 70% and shortens temperature ramp-up time by up to 80%, offering substantial gains in cycle time optimization and overall production sustainability.
Initially developed for manufacturers using PU RIM (Reaction Injection Molding), the technology is also compatible with a broader range of thermoset material processes, including HP-RTM and other composite molding applications.
Composite materials as integrated heating elements
At the core of NEXUS is an innovative approach: using the intrinsic properties of composite materials not only for structural reinforcement, but also as embedded heating elements within the mold itself.
Unlike traditional metal molds heated by circulating thermal fluids, the composite-based design enables extremely rapid temperature increases — reaching up to 30°C per minute. The system also provides highly precise, localized thermal control. Within the mold cavity, differentiated heating zones can be created with gradients separated by only a few millimeters, allowing tight control over chemical reaction kinetics in thermoset processing.
This level of precision opens new optimization possibilities, including customized heat distribution, calibrated transverse conductivity, and tailored heating rates based on specific part geometries and material behavior. The result is improved part quality, reduced thermal inertia, and potential raw material savings through more controlled expansion and curing.
Breaking the limits of traditional mold heating
Conventional mold heating systems based on metal tooling and thermal fluids typically face inherent efficiency limitations. Even when optimized, they rarely exceed around 75% energy efficiency and are constrained by significant thermal inertia, which slows ramp-up times and affects overall production responsiveness.
NEXUS was developed to overcome these structural constraints. By heating only the required areas within the mold and minimizing unnecessary heat dispersion, the system reduces energy waste and simplifies plant infrastructure. Eliminating thermal fluids also removes the need for complex piping networks and reduces operational risks associated with fluid handling.
A decade of R&D and validation
The development of NEXUS began in 2015, with the objective of improving efficiency in RIM and HP-RTM processes. Due to limited published research on using composites as active heating elements, CANNON conducted extensive internal electrical and thermal testing to understand material behavior under operational conditions.
Using the collected data, the company developed a mathematical simulation model of a composite mold with integrated heating. Prototype composite plates were manufactured and tested to validate simulation results, optimize heater layout, and refine material layering strategies before building the first full demonstration mold.
Field testing under real RIM polyurethane foam production conditions confirmed the theoretical performance gains. Parts produced with the NEXUS system matched the quality achieved with conventional technologies, while energy consumption dropped by more than 70%. Mold heat-up time was reduced from approximately one hour to around eight minutes, significantly improving production flexibility.
Supporting sustainable manufacturing goals
Beyond productivity gains, NEXUS aligns with broader sustainable manufacturing objectives, including Responsible Consumption and Production principles. By enabling precise temperature control, manufacturers can optimize reaction performance, maximize material expansion, and reduce raw material usage.
The elimination of hazardous thermal fluids simplifies overall energy infrastructure and lowers environmental impact, making NEXUS particularly attractive for companies seeking to improve both energy efficiency and ESG performance in composite and polyurethane manufacturing.
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