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Processes
Special Issues
Development and Characterization of Advanced Polymer Nanocomposites
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Development and Characterization of Advanced Polymer Nanocomposites

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Chemical Processes and Systems".

Deadline for manuscript submissions: 30 November 2025 | Viewed by 4872

Special Issue Editors

Dr. Md Nizam Uddin

E-Mail Website
Guest Editor
Division of Engineering, Texas A&M University-Texarkana, 7101 University Ave, Texarkana, TX 75503, USA
Interests: nanomaterials; polymer nanocomposites; bionanocomposites
Special Issues, Collections and Topics in MDPI journals
Dr. Faycal Znidi

E-Mail Website
Guest Editor
Division of Engineering, Texas A&M University-Texarkana, 7101 University Ave, Texarkana, TX 75503, USA
Interests: energy systems; graphene based solar cell materials; nanocomposites

Special Issue Information

Dear Colleagues,

Polymer nanocomposites have emerged as a promising class of materials due to their enhanced mechanical, thermal, electrical, and barrier properties, which surpass those of traditional composites. Various filler materials, i.e., nanoparticles, nanorods, nanotubes, quantum dots, and carbon-based materials (such as graphene, CNTs, carbon nano-onions, carbon nanoflowers, carbon dots), can be incorporated into polymer matrices through chemical synthesis or physical blending to enhance material performance. Achieving a uniform dispersion of these fillers within the polymer matrix is a critical challenge in nanomaterial technology, as it significantly influences the overall properties and effectiveness of the resulting nanocomposites. This Special Issue will focus on the latest advancements in the development, synthesis, characterization, and applications of advanced polymer nanocomposites. This Special Issue aims to cover a wide range of topics, including the integration of various nanofillers such as carbon nanotubes, graphene, nano-clays, metallic nanoparticles, and natural nanomaterials into polymer matrices. We invite research articles and reviews that explore different fabrication techniques—such as additive manufacturing, solution blending, melt processing, electrospinning, and in situ polymerization—and their effects on the microstructure and performance of nanocomposites. This Special Issue will also focus on the applications of advanced polymer nanocomposites in areas such as aerospace, automotives, electronics, energy storage, packaging, and biomedicine. Contributions addressing the environmental impact and sustainability of these materials, as well as the development of biodegradable nanocomposites, are highly encouraged.

Topics of interest for this Special Issue include, but are not limited to, the following:

  1. Synthesis and characterization of advanced polymer nanocomposites;
  2. Development of hybrid nanocomposites;
  3. Growth, properties, and applications of bionanocomposites;
  4. Theoretical and experimental research, knowledge, and new ideas in polymer nanocomposites;
  5. Green polymer nanocomposites with environmental sustainability;
  6. Additive manufacturing of polymer nanocomposites based on 3D or 4D printing;
  7. Manufacturing polymer nanocomposites using advanced technologies;
  8. Multifunctional properties and commercial applications of advanced polymer nanocomposites.

Dr. Md Nizam Uddin
Dr. Faycal Znidi
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 100 words) can be sent to the Editorial Office for announcement on this website.

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. Processes is an international peer-reviewed open access monthly 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 2400 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 nanocomposites
  • bionanocomposites
  • green polymer nanocomposites
  • characterization
  • additive manufacturing

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Published Papers (7 papers)

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Research

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14 pages, 8491 KiB  
Article
Tailored Polylactic Acid/Polycaprolactone Blends with Excellent Strength–Stiffness and Shape Memory Capacities
by Todor Batakliev, Vladimir Georgiev, Evgeni Ivanov, Verislav Angelov and Rumiana Kotsilkova
Processes 2025, 13(5), 1328; https://doi.org/10.3390/pr13051328 - 26 Apr 2025
Viewed by 74
Abstract
The present work deals with the mixing of two green polymers at several definite ratios that led to the receiving of biodegradable polylactic acid (PLA)/polycaprolactone (PCL) blends possessing well-expressed macromechanical and shape memory properties. Four non-compatibilized polymer compositions were prepared by using a [...] Read more.
The present work deals with the mixing of two green polymers at several definite ratios that led to the receiving of biodegradable polylactic acid (PLA)/polycaprolactone (PCL) blends possessing well-expressed macromechanical and shape memory properties. Four non-compatibilized polymer compositions were prepared by using a twin-screw melt extrusion technique, allowing for a homogeneous dispersion of the PCL droplets in the PLA matrix and higher interfacial adhesion between the two phases. The mechanical behavior of the specimens was estimated by tensile experiments conducted at three particular crosshead velocities. It was established that the addition of PCL as a soft segment redounded to an increment of the toughness and elongation at ultimate strength of the polymer composite at the expense of the maximum tensile stress and Young’s modulus. These latter two parameters were found to be more sensitive, in terms of reaching high values, to the content of PLA as a hard segment in the polymer blend. Performing thermoresponsive shape memory tests disclosed an overwhelming reversibility between the temporary and permanent states of the composite materials, including significant shape fixation (Rf) and shape recovery (Rr) rates. SEM analysis of the PLA/PCL compositions revealed a distinct phase-separated microstructure, confirming the immiscibility of the two polymers in the blend. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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32 pages, 72179 KiB  
Article
Impact of Substrate Type on the Properties of Cast Biodegradable Starch-Based Films
by Tomasz Tadeusz Murawski, Zuzanna Żołek-Tryznowska and Jerzy Szałapak
Processes 2025, 13(4), 1197; https://doi.org/10.3390/pr13041197 - 15 Apr 2025
Viewed by 201
Abstract
Biodegradable films are a viable alternative to conventional plastics, thereby contributing to environmental pollution reduction. This study investigates the impact of substrate type on the properties of starch-based films produced using a plasticizer-assisted casting method. Four different substrates, namely, glass, copper, copper-free laminate, [...] Read more.
Biodegradable films are a viable alternative to conventional plastics, thereby contributing to environmental pollution reduction. This study investigates the impact of substrate type on the properties of starch-based films produced using a plasticizer-assisted casting method. Four different substrates, namely, glass, copper, copper-free laminate, and Teflon®, were evaluated, addressing a research gap in which previous studies primarily focused on film composition. The films were analyzed for color, tensile strength, surface free energy, and surface morphology using optical and electron microscopy. The results demonstrated a substrate-dependent impact on surface properties, particularly optical transparency, surface roughness, and adhesion. The films cast on glass and laminate exhibited higher transparency and lower roughness, while copper substrate induced micro-striations and strong adhesion. Teflon® substrates replicated surface imperfections, which may be advantageous for optical applications, but caused film delamination. Tensile strength did not show statistically significant differences across substrates, although reduced elongation was observed for the films cast on Teflon®. Water vapor permeability was also not significantly affected, indicating a dominant role of bulk material properties. It averaged 25 kg per day per square meter, which means high vapor permeability. Surface free energy analysis revealed marked variations between top and bottom layers, with values ranging from 35 to 70 mJ·m⁻2 depending on the substrate. These findings confirm that the type of casting substrate plays a critical role in determining the surface and optical properties of starch-based films, even at the laboratory scale. This study provides new insights into substrate–film interactions and establishes a foundation for optimizing biodegradable film fabrication for industrial and application-specific needs. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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20 pages, 5836 KiB  
Article
Biodegradable Polymer Composites Based on Polypropylene and Hybrid Fillers for Applications in the Automotive Industry
by Alina Ruxandra Caramitu, Magdalena Valentina Lungu, Romeo Cristian Ciobanu, Ioana Ion, Delia Pătroi, Beatrice Gabriela Sbârcea, Virgil Emanuel Marinescu and Doina Constantinescu
Processes 2025, 13(4), 1078; https://doi.org/10.3390/pr13041078 - 3 Apr 2025
Viewed by 380
Abstract
This study focuses on the development and characterization of biodegradable polymer composites consisting of a polypropylene (PP) matrix, carbon black pigment, and hybrid fillers. The fillers incorporated into these composites consisted of a blend of fibers and particles derived from natural, biodegradable materials, [...] Read more.
This study focuses on the development and characterization of biodegradable polymer composites consisting of a polypropylene (PP) matrix, carbon black pigment, and hybrid fillers. The fillers incorporated into these composites consisted of a blend of fibers and particles derived from natural, biodegradable materials, such as flax fibers (FFs) and wood flour (WF) particles. The compositions of polymer material were expressed as PP/FF/WF weight ratios of 100/0/0, 70/5/25, and 70/10/20. The polymer materials were prepared using conventional plastic processing methods like extrusion to produce composite mixtures, followed by melt injection to manufacture the samples needed for characterization. The structural characterization of the polymer materials was conducted using optical microscopy and X-ray diffraction (XRD) analyses, while thermal, mechanical, and dielectric properties were also evaluated. Additionally, their biodegradation behavior under mold exposure was assessed over six months. The results were analyzed comparatively, and the optimal composition was identified as the polymer composite containing the highest flax fiber content, namely PP + 10 wt.% flax fiber + 20 wt.% wood flour. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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15 pages, 3579 KiB  
Article
Mechanical, Morphological, and Electrical Characteristics of Cu-Loaded Acrylic Paint on a Fused Deposition Modeling Printed Polylactic Acid Surface
by Sudhir Kumar, Pulkit Tiwari and Seyed Saeid Rahimian Koloor
Processes 2025, 13(4), 1059; https://doi.org/10.3390/pr13041059 - 2 Apr 2025
Viewed by 314
Abstract
Fused deposition modeling (FDM) printing has become increasingly popular for exploring advanced material matrices with a polymeric base. This study uses a low-energy method to investigate the metallization process on a surface created by 3D printing. This involves using an acrylic-paint-based solution to [...] Read more.
Fused deposition modeling (FDM) printing has become increasingly popular for exploring advanced material matrices with a polymeric base. This study uses a low-energy method to investigate the metallization process on a surface created by 3D printing. This involves using an acrylic-paint-based solution to disperse the copper (Cu) powder on a polylactic acid (PLA) substrate, allowing for an evaluation of the fabricated samples’ mechanical, morphological, absorbance, and capacitance properties. The study findings indicate a gradual increase in tensile strength as the content of Cu in the acrylic paint layer on the PLA substrate increases. There was a clear and consistent increase in the tensile strength of the specimen, ranging from 13.5 MPa (sample 1) to 15.6 MPa (sample 5). Similarly, the percentage of strain at failure also showed a noticeable increase, ranging from 4.2% (sample 1) to 8.6% (sample 5). The scanning electron microscopy (SEM) investigation revealed the presence of completely enveloped Cu particles in acrylic paint on the FDM-printed surface of the PLA. The Ultraviolet–Visible Diffuse Reflectance Spectroscopy (UV–Vis DRS) indicated a significant change in the absorbance pattern as the copper content in the layer increased. The augmented absorbance values serve as an advantage because they demonstrate enhanced UV light interaction, which correlates with the increase in capacitance measurements of 6 to 8 pF. This result suggests that the fabricated sample potentially leads to favorable alterations in material characteristics for applications that demand stable capacitance alongside improved mechanical properties. The SEM analysis supported the observed trends. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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18 pages, 6921 KiB  
Article
Chitosan Nanoparticulate System Loaded with Cannabidiol: A Topical Formulation for Potential Alopecia Management
by Josenildo R. Oliveira, Débora S. Lopes, Milena C. S. Barbosa, Henrique N. Silva, Marcus V. L. Fook, Suédina M. L. Silva, João M. P. Q. Delgado and Antonio G. B. Lima
Processes 2025, 13(3), 617; https://doi.org/10.3390/pr13030617 - 21 Feb 2025
Cited by 1 | Viewed by 396
Abstract
This study explores an innovative topical formulation to treat alopecia by encapsulating cannabidiol (CBD) in chitosan nanoparticles. CBD, widely known for its anti-inflammatory, antioxidant, and endocannabinoid-modulating effects, shows significant potential for treating alopecia, a condition characterized by hair loss influenced by genetic, hormonal, [...] Read more.
This study explores an innovative topical formulation to treat alopecia by encapsulating cannabidiol (CBD) in chitosan nanoparticles. CBD, widely known for its anti-inflammatory, antioxidant, and endocannabinoid-modulating effects, shows significant potential for treating alopecia, a condition characterized by hair loss influenced by genetic, hormonal, or environmental factors. However, its low water solubility presents a significant challenge for topical applications. To address this issue, chitosan nanoparticles were synthesized using chitosan of reduced molecular mass (270 kDa) with an acetylation level of 12%, β-glycerophosphate as a crosslinking agent, and 1% glycerol to improve CBD encapsulation efficiency. Physicochemical characterization using scanning electron microscopy (SEM), zeta potential measurement, and Fourier transform infrared spectroscopy (FTIR) revealed that the β-glycerophosphate concentration impacted nanoparticle size and the electrostatic interactions between chitosan’s primary amines and phosphate groups of β-glycerophosphate. Among the tested concentrations (0.05, 0.1, 0.2, and 0.25 mol/L), 0.20 mol/L produced the smallest nanoparticles (390 nm), which were further optimized to encapsulate CBD, reaching a particle size of 227 nm. This optimized formulation may improve the solubility of CBD and enable targeted and sustained delivery to hair follicles. These findings highlight chitosan nanoparticles as a cutting-edge and scalable platform for transdermal delivery of hydrophobic bioactive compounds, presenting a promising approach for the effective management of alopecia. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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16 pages, 7491 KiB  
Article
Effects of Surface Treatment on Adhesive Performance of Composite-to-Composite and Composite-to-Metal Joints
by Nikhil Paranjpe, Md. Nizam Uddin, Akm Samsur Rahman and Ramazan Asmatulu
Processes 2024, 12(12), 2623; https://doi.org/10.3390/pr12122623 - 21 Nov 2024
Cited by 1 | Viewed by 1894
Abstract
This study deals with the long-running challenge of joining similar and dissimilar materials using composite-to-composite and composite-to-metal joints. This research was conducted to evaluate the effects of surface morphology and surface treatments on the mechanical performance of adhesively bonded joints used for the [...] Read more.
This study deals with the long-running challenge of joining similar and dissimilar materials using composite-to-composite and composite-to-metal joints. This research was conducted to evaluate the effects of surface morphology and surface treatments on the mechanical performance of adhesively bonded joints used for the aircraft industry. A two-segment, commercially available, toughened epoxy was chosen as the adhesive. Unidirectional carbon fiber prepreg and aluminum 2021-T3 alloys were chosen for the composite and metal panels, respectively. Surface treatment of the metal included corrosion elimination followed by a passive surface coating of Alodine®. A combination of surface treatment methods was used for the composite and metal specimens, including detergent cleaning, plasma exposure, and sandblasting. The shear strength of the single-lap adhesive joint was evaluated according to the ASTM D1002. Ultraviolet (UV) and plasma exposure effects were studied by measuring the water contact angles. The test results showed that the aluminum adherent treated with sandblasting, detergent, and UV irradiation resulted in the strongest adhesive bonding of the composite-to-composite panels, while the composite-to-metal sample cleaned only with detergent resulted in the least bonding strength. The failure strain of the composite-to-composite bonding was reduced by approximately 50% with only sandblasting. However, extended treatment did not introduce additional brittleness in the adhesive joint. The bonding strength of the composite-to-composite panel improved by approximately 35% with plasma treatment alone because of the better surface functionalization and bonding strength. In the composite-to-aluminum bonding process, exposing the aluminum surface to UV resulted in 30% more joint strength compared to the Alodine® coating, which suggests the origination of higher orders of magnitude of covalent groups from the surface. A comparison with published results found that the joint strengths in both similar and dissimilar specimens are higher than most other results. Detailed observations and surface analysis studies showed that the composite-to-composite bonding mainly failed due to adhesive and cohesive failures; however, failure of the composite-to-aluminum bonding was heterogeneous, where adhesive failure occurred on the aluminum side and substrate failure occurred on the composite side. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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Review

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19 pages, 2117 KiB  
Review
Polymer Nanocomposites with Optimized Nanoparticle Dispersion and Enhanced Functionalities for Industrial Applications
by Md Mahbubur Rahman, Karib Hassan Khan, Md Mahadi Hassan Parvez, Nelson Irizarry and Md Nizam Uddin
Processes 2025, 13(4), 994; https://doi.org/10.3390/pr13040994 - 26 Mar 2025
Viewed by 679
Abstract
Polymer nanocomposites (PNCs) are a versatile class of materials known for their enhanced mechanical, thermal, electrical, and barrier properties, with the latter referring to resistance against the permeation of gases and liquids. Achieving optimal nanoparticle dispersion within the polymer matrix is essential to [...] Read more.
Polymer nanocomposites (PNCs) are a versatile class of materials known for their enhanced mechanical, thermal, electrical, and barrier properties, with the latter referring to resistance against the permeation of gases and liquids. Achieving optimal nanoparticle dispersion within the polymer matrix is essential to fully realizing these advantages. This study investigates strategies for improving nanoparticle dispersion and examines the impact of controlled dispersion on the resulting nanocomposite properties. Various methods, including in situ polymerization, twin screw extrusion, sol–gel processes, nanoparticle surface modification, solution casting, and advanced compounding techniques such as additive manufacturing and self-healing composites were explored to enhance dispersion and improve the compatibility between nanoparticles and polymers. The synergy between improved dispersion and enhanced functionalities—such as increased mechanical strength, thermal stability, conductivity, and chemical resistance—makes these nanocomposites highly valuable for industrial applications in sectors such as the automotive, aerospace, electronics, pharmaceuticals, and packaging industries. The key recommendations based on our findings highlight how customized nanocomposites can address specific industrial challenges, fostering innovation in materials science and engineering. Full article
(This article belongs to the Special Issue Development and Characterization of Advanced Polymer Nanocomposites)
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