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Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their...
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Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their Composites

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: 30 September 2026 | Viewed by 9147

Special Issue Editors

Dr. Maoyuan Li

E-Mail Website
Guest Editor
Department of Aeronautics, Xiamen University, Xiamen 361005, China
Interests: polymer; polymer-based composites; thermodynamic property; polymer processing; molecular dynamics; computational fluid dynamics; finite element method
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Hui Wang

E-Mail Website
Guest Editor
School of Automotive Engineering, Wuhan University of Technology, Wuhan 430070, China
Interests: polymers and their composites; forming process; numerical simulation; process optimization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

High-performance polymers and their composite materials play a crucial role in a wide range of industrial applications, including aerospace, automotive, and energy sectors, due to their exceptional mechanical properties, thermal stability, and lightweight characteristics.

The Special Issue presents cutting-edge research on innovative manufacturing techniques, such as advanced molding, additive manufacturing, and hybrid processes, all designed to enhance material performance and production efficiency. Additionally, it explores state-of-the-art numerical simulations that model the behavior of these complex materials under various processing conditions, offering valuable insights into process optimization and the design of new materials with tailored properties. The contributions also examine the integration of process optimization strategies, leveraging data-driven approaches and machine learning techniques to streamline production, reduce waste, and minimize energy consumption. Any reports and reviews covering the aspect of manufacturing techniques and multiscale modeling and simulations are welcomed, using methods including but not limited to the above-mentioned methods.

Dr. Maoyuan Li
Prof. Dr. Hui Wang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • polymer
  • polymer-based composite
  • manufacturing
  • computational modeling
  • process optimization

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Published Papers (5 papers)

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Research

22 pages, 8950 KB  
Article
Six-Axis Robotic Milling for Enhancing Surface Quality and Dimensional Accuracy of Fused Granular Fabrication Parts
by Rui Zhang, Xiping Li, Youqiang Yao, Sisi Wang, Yu Zhou and Zhonglue Hu
Polymers 2026, 18(5), 608; https://doi.org/10.3390/polym18050608 - 28 Feb 2026
Viewed by 587
Abstract
Fused granular fabrication (FGF) offers high deposition efficiency and low material cost for large-scale mold production, but commonly yields parts with surface defects and dimensional deviations. This study develops a six-axis robotic post-processing workstation that integrates multi-DOF toolpath planning and real-time communication to [...] Read more.
Fused granular fabrication (FGF) offers high deposition efficiency and low material cost for large-scale mold production, but commonly yields parts with surface defects and dimensional deviations. This study develops a six-axis robotic post-processing workstation that integrates multi-DOF toolpath planning and real-time communication to flexibly machine FGF components with complex geometries. Using short-fiber-reinforced polypropylene (PP-GF), robotic milling experiments were performed, and spindle speed, feed rate, and cutting depth were systematically optimized to enhance surface quality and dimensional accuracy. The NSGA-III algorithm optimizes parameters, thereby increasing machining efficiency by 4.9% and reducing surface roughness by 12.35%. Results show that the proposed platform effectively improves the machining performance of FGF-printed parts, demonstrating its feasibility for high-precision post-processing. The work provides a practical technical route for the hybrid additive–subtractive manufacturing of large 3D-printed structures. Full article
(This article belongs to the Special Issue Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their Composites)
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24 pages, 11079 KB  
Article
Hydrothermal Pretreatment Plus Supercritical CO2 Foaming as a Novel Route to Improving Polymer Structures for Biomedical Applications—Part 1: Preliminary Screening for Individual and Combined Polymers
by M. Belén García-Jarana, Ramón Terroba, José M. Vázquez-Fernández, Diego Valor, Clara Pereyra and Juan R. Portela
Polymers 2026, 18(1), 81; https://doi.org/10.3390/polym18010081 - 27 Dec 2025
Viewed by 504
Abstract
Degradable polymers are essential in tissue engineering due to their capacity to mimic the extracellular matrix and promote regeneration. To be functional, they require interconnected porous structures that allow for nutrient exchange and cell migration. Although methods exist to optimize porosity, many compromise [...] Read more.
Degradable polymers are essential in tissue engineering due to their capacity to mimic the extracellular matrix and promote regeneration. To be functional, they require interconnected porous structures that allow for nutrient exchange and cell migration. Although methods exist to optimize porosity, many compromise biocompatibility because pore-forming substances are used. In this context, hydrothermal pretreatment emerges as a promising technique to simultaneously improve both the porosity and mechanical properties of polymers without using potentially toxic reagents. This study proposes a novel route that combines hydrothermal pretreatment with supercritical CO2 foaming, evaluating whether the structures obtained present better characteristics for biomedical applications compared to those obtained using supercritical CO2 foaming alone. A screening of this novel route has been tested on individual polymers (PCL, PLA, PLGA, PVA, PBS, chitosan) and various binary combinations (PCL-PBS, chitosan-PBS, PVA-PBS, PLGA-PEDOT: PSS). The resulting materials were characterized using electron microscopy to analyze pore diameter and distribution, as well as structural stability and homogeneity. For the individual polymers, the hydrothermal pretreatment clearly improved the results obtained. However, most polymer combinations showed drawbacks such as mass losses, heterogeneity, or unsatisfactory pore formation. This research highlights the potential of hydrothermal pretreatment to optimize scaffolds, which is crucial for viability in biomedical applications. Full article
(This article belongs to the Special Issue Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their Composites)
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23 pages, 4352 KB  
Article
Quantifying Inter-Ply Friction and Clamping Effects via an Experimental–Numerical Framework: Advancing Non-Coherent Deformation Control of Uncured Metal–Fiber-Reinforced Polymer Laminates
by Yunlong Chen and Shichen Liu
Polymers 2025, 17(17), 2330; https://doi.org/10.3390/polym17172330 - 28 Aug 2025
Viewed by 4200
Abstract
Pre-stacked uncured metal–fiber-reinforced polymer (FRP) laminates, which are critical for aerospace components like double-curved fuselage panels, wing ribs, and engine nacelles, exhibit better deformation behavior than their fully cured counterparts. However, accurate process simulation requires precise material characterization and process optimization to achieve [...] Read more.
Pre-stacked uncured metal–fiber-reinforced polymer (FRP) laminates, which are critical for aerospace components like double-curved fuselage panels, wing ribs, and engine nacelles, exhibit better deformation behavior than their fully cured counterparts. However, accurate process simulation requires precise material characterization and process optimization to achieve a defect-free structural design. This study focuses on two core material behaviors of uncured laminates—inter-ply friction at metal–prepreg interfaces and out-of-plane bending—and optimizes process parameters for their non-coherent deformation. Experimental tests included double-lap sliding tests (to quantify inter-ply friction) and clamped-beam bending tests (to characterize out-of-plane bending); a double-curved dome part was designed to assess the effects of the material constituent, fiber orientation, inter-ply friction, and clamping force, with validation via finite element modeling (FEM) in Abaqus software. The results indicate that the static–kinetic friction model effectively predicts inter-ply friction behavior, with numerical friction coefficient–displacement trends closely matching experimental data. Additionally, the flexural bending model showed that greater plastic deformation in metal layers increased bending force while reducing post-unloading spring-back depth. Furthermore, for non-coherent deformation, higher clamping forces improve FRP prepreg deformation and mitigate buckling, but excessive plastic deformation raises metal cracking risk. This work helps establish a combined experimental–numerical framework for the defect prediction and process optimization of complex lightweight components, which address the core needs of modern aerospace manufacturing. Full article
(This article belongs to the Special Issue Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their Composites)
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19 pages, 4397 KB  
Article
Thermal History-Dependent Deformation of Polycarbonate: Experimental and Modeling Insights
by Maoyuan Li, Haitao Wang, Guancheng Shen, Tianlun Huang and Yun Zhang
Polymers 2025, 17(15), 2096; https://doi.org/10.3390/polym17152096 - 30 Jul 2025
Viewed by 1102
Abstract
The deformation behavior of polymers is influenced not only by service conditions such as temperature and the strain rate but also significantly by the formation process. However, existing simulation frameworks typically treat injection molding and the in-service mechanical response separately, making it difficult [...] Read more.
The deformation behavior of polymers is influenced not only by service conditions such as temperature and the strain rate but also significantly by the formation process. However, existing simulation frameworks typically treat injection molding and the in-service mechanical response separately, making it difficult to capture the impact of the thermal history on large deformation behavior. In this study, the deformation behavior of injection-molded polycarbonate (PC) was investigated by accounting for its thermal history during formation, achieved through combined experimental characterization and constitutive modeling. PC specimens were prepared via injection molding followed by annealing at different molding/annealing temperatures and durations. Uniaxial tensile tests were conducted using a Zwick universal testing machine at strain rates of 10−3–10−1 s−1 and temperatures ranging from 293 K to 353 K to obtain stress–strain curves. The effects of the strain rate, testing temperature, and annealing conditions were thoroughly examined. Building upon a previously proposed phenomenological model, a new constitutive framework incorporating thermal history effects during formation was developed to characterize the large deformation behavior of PC. This model was implemented in ABAQUS/Explicit using a user-defined material subroutine. Predicted stress–strain curves exhibit excellent agreement with the experimental data, accurately reproducing elastic behavior, yield phenomena, and strain-softening and strain-hardening stages. Full article
(This article belongs to the Special Issue Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their Composites)
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15 pages, 3143 KB  
Article
Molecular Dynamics Simulation of Plasticizing Effect of Mixed Dioctyl Phthalate and Isosorbide Diheptanoate on Polyvinyl Chloride Material
by Qin Lei, Xijian Yi, Wenxi Yu, Juan Cheng, Siyu Ou, Qiong Xue and Haiyun Jiang
Polymers 2025, 17(12), 1655; https://doi.org/10.3390/polym17121655 - 14 Jun 2025
Cited by 4 | Viewed by 2159
Abstract
A molecular dynamics simulation was adopted to investigate the plasticizing effect of polyvinyl chloride (PVC) and its mechanism by blending isosorbide heptylate (SDH) with the traditional plasticizer dioctyl phthalate (DOP) and to explore the feasibility of SDH partially replacing DOP in PVC film. [...] Read more.
A molecular dynamics simulation was adopted to investigate the plasticizing effect of polyvinyl chloride (PVC) and its mechanism by blending isosorbide heptylate (SDH) with the traditional plasticizer dioctyl phthalate (DOP) and to explore the feasibility of SDH partially replacing DOP in PVC film. The results demonstrated that the difference in the solubility parameter between SDH and PVC was smaller than that between DOP and PVC, indicating the superior compatibility of SDH with PVC. This enhanced compatibility was further supported by the significantly higher interaction energy between SDH and PVC compared to that between DOP and PVC, primarily attributed to the stronger interactions formed between the polar functional groups in the SDH molecules and the PVC’s molecular chains. The analysis of the glass transition temperature demonstrated that the plasticizing effect of the SDH/DOP mixed plasticizer on the PVC exhibited intermediate behavior between that of pure SDH and DOP systems, showing a decreasing trend with an increasing proportion of SDH. An analysis of the radial distribution function further confirmed that the probability of hydrogen bond formation between the SDH and PVC molecules was significantly higher than that between DOP and PVC, contributing to the strong interaction between the SDH and PVC. From the analysis of the plasticizer’s diffusion, it was clearly concluded that the migration resistance of SDH was superior to that of DOP. These research findings can provide fundamental data and guidance for the strategy of partially replacing DOP with SDH. Full article
(This article belongs to the Special Issue Manufacturing, Simulation and Process Optimization of High-Performance Polymers and Their Composites)
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