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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Polymeric Materials".

Deadline for manuscript submissions: 20 June 2025 | Viewed by 16268

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Dr. Joanna Izdebska-Podsiadły

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Department of Printing Technology, Institute of Mechanics and Printing, Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, Konwiktorska 2, 00-217 Warsaw, Poland
Interests: biodegradable films; packaging; flexographic printing; 3D printing; printing inks; plasma modification; wettability and adhesion

Special Issue Information

Dear Colleagues,

With the increasing demand for plastics in various industries, it has become crucial to find innovative techniques to process them. Hence, recent research in polymer and plastic processing have focused on improving the efficiency and sustainability of these materials.

A key focus in this field is to develop bio-based materials, derived from renewable sources such as plants, to replace traditional polymers. These bio-based polymers not only reduce our dependence on fossil fuels, but also offer better biodegradability and reduced environmental impact. However, there are challenges in marking, decorating or printing on them. For instance, to print on the plastics developed for packaging, the problem of proper wettability and adhesion of the ink to the non-absorbent substrate must be solved; the solution is to modify the polymeric materials using physical or chemical methods to achieve high-quality printing or to allow for further processing.

Another important research endeavor is the development of new methods to enhance the recycling capabilities of plastics or to devise ways to effectively recycle the ones that are highly non-degradable. Researchers are investigating the potential of new technologies such as chemical recycling, which breaks down plastics at a molecular level, enabling them to be reused more efficiently.

Additionally, researchers are aiming to optimize the processing techniques of polymers and plastics using novel methods, such as 3D printing and injection molding, to achieve higher precision, faster production, better design flexibility, reduce manufacturing costs, and improve the overall quality and performance of the final products.

This Special Issue aims to collate papers addressing any and all aspects of developing sustainable and efficient ways of polymer and plastic processing. Some potential topics include polymer processing, plastic recycling, bio-based polymers, sustainable materials, plasma modification of polymeric materials, films printing, 3D printing, injection molding, efficiency, and sustainability.

Dr. Joanna Izdebska-Podsiadły
Guest Editor

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Keywords

polymer processing
plastic recycling
bio-based polymers
sustainable materials
plasma modification of polymeric materials
films printing
3D printing
injection molding, efficiency
sustainability

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Published Papers (9 papers)

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Research

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16 pages, 2300 KiB

Open AccessArticle

Multi-Objective Optimization of Injection Molding Process Parameters for Junction Boxes Based on BP Neural Network and NSGA-II Algorithm

by Tengjiao Hong, Dong Huang, Fengjuan Ding, Liyong Zhang, Fulong Dong and Lei Chen

Materials 2025, 18(3), 577; https://doi.org/10.3390/ma18030577 - 27 Jan 2025

Viewed by 870

Abstract

Many factors affect the quality of the injection molding of plastic products, including the process parameters, mold materials, type and geometry of plastic parts, cooling system, pouring system, etc. A multi-objective optimization method for injection molding process parameters based on the BP neural network and NSGA-II algorithm is proposed to address the problem of product quality defects caused by unreasonable process parameter settings. Taking the junction box shell as the object, numerical simulation was carried out using Moldflow2019 software and a six-factor five-level orthogonal experiment was designed to explore the influence of injection molding process parameters, such as the mold temperature, melt temperature, injection pressure, holding pressure, holding time, and cooling time, on the volume shrinkage rate and warpage deformation of the junction box. Based on a numerical simulation, the BP neural network and NSGA-II algorithm were used to optimize the optimal combination of injection molding process parameters, volume shrinkage rate, and warpage deformation. The research results indicate that the melt temperature has the most significant impact on the quality of the injection molding of junction boxes, followed by the holding time, holding pressure, cooling time, injection pressure, and mold temperature. After optimization using the BP neural network and the NSGA-II algorithm, the optimal process parameter combination was obtained with a melt temperature of 230.03 °C, a mold temperature of 51.27 °C, an injection pressure of 49.13 MPa, a holding pressure of 69.01 MPa, a holding time of 15.48 s, and a cooling time of 34.91 s. At this time, the volume shrinkage rate and warpage deformation of the junction box were 6.905% and 0.991 mm, respectively, which decreased by 33.2% and 3.8% compared to the average volume shrinkage rate (10.34884%) and warpage deformation (1.030764 mm) before optimization. The optimization effect was significant. In addition, the errors between the volume shrinkage rate and warpage deformation predicted by BP-NSGA-II and the simulated values using Moldflow software were 1.9% and 3.4%, respectively, indicating that the optimization method based on the BP neural network model and NSGA-II algorithm is reliable. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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18 pages, 4963 KiB

Open AccessArticle

Polyacrylamide Hydrogel Containing Starch and Sugarcane Bagasse Ash: Synthesis, Characterisation, and Application in Cement Pastes and Mortars

by Ana Elizabete Nunes Pereira, Edson Araujo de Almeida, Fábio Rodrigo Kruger, Edson Cavalcanti da Silva-Filho and Edvani Curti Muniz

Materials 2024, 17(23), 5889; https://doi.org/10.3390/ma17235889 - 1 Dec 2024

Viewed by 821

Abstract

Internal curing is a process based on the addition of materials that function as water reservoirs in cementitious media. Superabsorbent hydrogels are an alternative that can be used as an internal curing agent, as they have the ability to absorb and release water in a controlled manner. In the present work, superabsorbent hydrogels based on crosslinked polyacrylamide in the presence of starch and sugarcane bagasse ash (SCBA) were developed and applied to mortars as an internal curing agent. The synthesized hydrogels were evaluated by SEM, FTIR, and swelling analysis. Cement pastes and mortars were produced using different amounts of hydrogel (0.03%, 0.06%, and 0.1% by weight). An analysis of the cement pastes and mortars revealed that hydrogel contributes to hydration, thus improving the quality of the product. Furthermore, the addition of 0.03% hydrogel by weight increased the mechanical resistance of the mortars in up to 26.8% at 28 days of curing as compared with reference (without hydrogel). To the best of our knowledge, this is the first study to use a hydrogel based on polyacrylamide crosslinked with starch and SCBA as a curing agent for mortars and cement pastes. This approach is environmentally friendly, because it uses a natural product (starch) and a byproduct from the sugarcane industry (SCBA). Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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18 pages, 5411 KiB

Open AccessArticle

Hydrogels Based on Polyacrylamide and Pectin Containing Rice Husk Ash: Preparation, Characterization and Application in Formulation of Cementitious Materials

by Ruth Hevellen Sousa Rodrigues, Edson Araujo de Almeida, Fábio Rodrigo Kruger, Edson Cavalcanti Silva-Filho and Edvani Curti Muniz

Materials 2024, 17(23), 5746; https://doi.org/10.3390/ma17235746 - 24 Nov 2024

Cited by 1 | Viewed by 908

Abstract

Superabsorbent polymers (PSAs) have been extensively studied to act as internal curing agents in cementitious materials, as they have the characteristic of absorbing and releasing water in a controlled manner, which can contribute to the hydration process of a cementitious medium during its consolidation. Thus, hydrogels consisting of polyacrylamide (PAAm), pectin (Pec) and rice husk ash (RHA) were synthesized to be applied in cementitious matrices. In addition, the PSAs were characterized by FTIR, SEM, and XRD. For evaluating the usage of hydrogels as internal curing agents, different hydrogel contents—0.03, 0.06, and 0.1 (wt-%, relative to cementitious components)—were used for mortar preparation. The mechanical strengths of the cementitious materials were evaluated at day 7 and day 28 during the curing process. The addition of PSAs to the mortars caused an increase in mechanical resistance such that the 0.06% content presented better performance at day 7 of curing (4.07% higher) and at day 28 of curing (8.06% higher) when compared with the reference mortar (without the addition of PSAs) in the same curing periods. This work demonstrates that the addition of PSAs contributes to the hydration of a cementitious material, improving the mechanical resistance of the studied mortars. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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9 pages, 2037 KiB

Open AccessCommunication

Polyacrylonitrile Composites Blended with Asphalt as a Low-Cost Material for Producing Synthetic Fibers: Rheology and Thermal Stability

by Artem V. Pripakhaylo, Alexei A. Tsypakin, Anton A. Klam, Andrei L. Andreichev, Andrei R. Timerbaev, Oksana V. Shapovalova and Rustam N. Magomedov

Materials 2024, 17(23), 5725; https://doi.org/10.3390/ma17235725 - 22 Nov 2024

Cited by 1 | Viewed by 719

Abstract

The results of rheological studies and thermal analysis of polymer compositions based on polyacrylonitrile copolymers (PAN) of different molecular weights and asphalt isolated by n-pentane solvent deasphalting are presented. It was found that the asphalt content in mixtures with PAN at the level of 10–30 wt.% improves the rheological properties of the polymer composite melt. In particular, the temperatures of extrusion and molding of fibers tend to reduce, and the time during which the melt retains its rheological characteristics necessary for extrusion is notably increased, from 43 to 92 min. Thermal analysis by DSC revealed no effect of asphalt additive in an amount of up to 30 wt.% on radical PAN cyclization and the subsequent stage of fiber stabilization. Our study proved the possibility of preparing polymer composites based on PAN and asphalt suitable for extrusion and eventual molding of continuous filaments of synthetic fibers with reduced cost of production. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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18 pages, 3856 KiB

Open AccessArticle

A New Double-Step Process of Shortening Fibers without Change in Molding Equipment Followed by Electron Beam to Strengthen Short Glass Fiber Reinforced Polyester BMC

by Michael C. Faudree and Yoshitake Nishi

Materials 2024, 17(9), 2036; https://doi.org/10.3390/ma17092036 - 26 Apr 2024

Viewed by 1155

Abstract

It is vital to maximize the safety of outdoor constructions, airplanes, and space vehicles by protecting against the impact of airborne debris from increasing winds due to climate change, or from bird strikes or micrometeoroids. In a widely-used compression-molded short glass fiber polyester bulk-molded compound (SGFRP-BMC) with 55% wt. CaCO₃ filler, the center of the mother panel has lower impact strength than the outer sections with solidification texture angles and short glass fiber (SGF) orientations being random from 0 to 90 degrees. Therefore, a new double-step process of: (1) reducing commercial fiber length without change in molding equipment; followed by a (2) 0.86 MGy dose of homogeneous low-voltage electron beam irradiation (HLEBI) to both sides of the finished samples requiring no chemicals or additives, which is shown to increase the Charpy impact value (a_uc) about 50% from 6.26 to 9.59 kJm⁻² at median-accumulative probability of fracture, P_f = 0.500. Shortening the SGFs results in higher fiber spacing density, S_f, as the thermal compressive stress site proliferation by action of the CTE difference between the matrix and SGF while the composite cools and shrinks. To boost impact strength further, HLEBI provides additional nano-compressive stresses by generating dangling bonds (DBs) creating repulsive forces while increasing SGF/matrix adhesion. Increased internal cracking apparently occurs, raising the a_uc. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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13 pages, 11887 KiB

Open AccessEditor’s ChoiceArticle

Degradation of Poly(ethylene terephthalate) Catalyzed by Nonmetallic Dibasic Ionic Liquids under UV Radiation

by Ruiqi Zhang, Xu Zheng, Xiujie Cheng, Junli Xu, Yi Li, Qing Zhou, Jiayu Xin, Dongxia Yan and Xingmei Lu

Materials 2024, 17(7), 1583; https://doi.org/10.3390/ma17071583 - 29 Mar 2024

Cited by 3 | Viewed by 1641

Abstract

Nonmetallic ionic liquids (ILs) exhibit unique advantages in catalyzing poly (ethylene terephthalate) (PET) glycolysis, but usually require longer reaction times. We found that exposure to UV radiation can accelerate the glycolysis reaction and significantly reduce the reaction time. In this work, we synthesized five nonmetallic dibasic ILs, and their glycolysis catalytic activity was investigated. 1,8-diazabicyclo [5,4,0] undec-7-ene imidazole ([HDBU]Im) exhibited better catalytic performance. Meanwhile, UV radiation is used as a reinforcement method to improve the PET glycolysis efficiency. Under optimal conditions (5 g PET, 20 g ethylene glycol (EG), 0.25 g [HDBU]Im, 10,000 µW·cm⁻² UV radiation reacted for 90 min at 185 °C), the PET conversion and BHET yield were 100% and 88.9%, respectively. Based on the UV-visible spectrum, it was found that UV radiation can activate the C=O in PET. Hence, the incorporation of UV radiation can considerably diminish the activation energy of the reaction, shortening the reaction time of PET degradation. Finally, a possible reaction mechanism of [HDBU]Im-catalyzed PET glycolysis under UV radiation was proposed. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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15 pages, 3273 KiB

Open AccessArticle

Development of a Recycling Process and Characterization of EVA, PVDF, and PET Polymers from End-of-Life PV Modules

by Marek Królikowski, Michał Fotek, Piotr Żach and Marcin Michałowski

Materials 2024, 17(4), 821; https://doi.org/10.3390/ma17040821 - 8 Feb 2024

Cited by 8 | Viewed by 3061

Abstract

Photovoltaic (PV) modules are highly efficient power generators associated with solar energy. The rapid growth of the PV industry will lead to a sharp increase in the waste generated from PV panels. However, electro-waste can be successfully used as a source of secondary materials. In this study, a unique procedure for recycling PV modules was developed. In the first stage, the aluminum frame and junction box, 18wt%. and 1wt%. of the module, respectively, were removed. The following stage was crucial, involving a mechanical–thermal method to remove the glass, which accounts for 70wt%. As a result, only 11wt%. of the initial mass of the PV was subjected to the next stage of chemical delamination, which reduced the amount of solvent used. Toluene was used to swell the ethylene vinyl acetate, EVA, and allow for the separation of the PV module. The effects of temperature and ultrasound on separation time were investigated. After the separation of silicon cells, metal ribbons, EVA, and the backsheet were obtained. The purity of the polymers was determined by FTIR and elemental analysis. Thermal properties were measured using DSC calorimetry to determine the basic parameters of the material. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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11 pages, 4642 KiB

Open AccessArticle

Study on the Printability of Starch-Based Films Using Ink-Jet Printing

by Zuzanna Żołek-Tryznowska, Katarzyna Piłczyńska, Tomasz Murawski, Arkadiusz Jeznach and Krzysztof Niczyporuk

Materials 2024, 17(2), 455; https://doi.org/10.3390/ma17020455 - 18 Jan 2024

Cited by 3 | Viewed by 1582

Abstract

Starch-based films are a valuable alternative to plastic materials that are based on fossil and petrochemical raw resources. In this study, corn and potato starch films with 50% glycerol as a plasticizer were developed, and the properties of films were confirmed by mechanical properties, surface free energy, surface roughness, and, finally, color and gloss analyses. Next, the films were overprinted using ink-jet printing with quick response (QR) codes, text, and pictograms. Finally, the print quality of the obtained prints was determined by optical density, color parameters, and the visual evaluation of prints. In general, corn films exhibit lower values of mechanical parameters (tensile strength, elongation at break, and Young Modulus) and water transition rate (11.1 mg·cm⁻²·h⁻¹) than potato starch film (12.2 mg·cm⁻²·h⁻¹), and water solubility is 18.7 ± 1.4 and 20.3 ± 1.2% for corn and potato film, respectively. The results obtained for print quality on starch-based films were very promising. The overprinted QR codes were quickly readable by a smartphone. The sharpness and the quality of the lettering are worse on potato film. At the same time, higher optical densities were measured on potato starch films. The results of this study show the strong potential of using starch films as a modern printing substrate. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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Review

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17 pages, 3623 KiB

Open AccessReview

Surface Modification of Polymers by Plasma Treatment for Appropriate Adhesion of Coatings

by Gregor Primc and Miran Mozetič

Materials 2024, 17(7), 1494; https://doi.org/10.3390/ma17071494 - 26 Mar 2024

Cited by 22 | Viewed by 4523

Abstract

In this study, recent advances in tailoring the surface properties of polymers for the optimization of the adhesion of various coatings by non-equilibrium gaseous plasma are reviewed, and important findings are stressed. Different authors have used various experimental setups and reported results that scatter significantly and are sometimes contradictory. The correlations between the processing parameters and the adhesion are drawn, and discrepancies are explained. Many authors have explained improved adhesion with the adjustment of the surface free energy or wettability of the polymer substrate and the surface tension of liquids used for the deposition of thin films. The adhesion force between the polymer substrate and the coating does not always follow the evolution of the surface wettability, which is explained by several effects, including the aging effects due to the hydrophobic recovery and the formation of an interlayer rich in loosely bonded low molecular weight fragments. Full article

(This article belongs to the Special Issue Recent Researches in Polymer and Plastic Processing)

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