Search Results (784)

Recycled thermoplastics offer a promising route for valorizing industrial residues and developing thermoplastic-bonded wood-based panels without added formaldehyde-based resins. In this study, experimental wood–polymer composite boards were produced from recycled acrylonitrile–butadiene–styrene (ABS) edge-banding waste used as the polymer matrix and industrial wood fibers used as the lignocellulosic reinforcement. The boards were manufactured at target densities of 800–1200 kg·m⁻³ and wood fiber contents of 10–30%, followed by the evaluation of selected physical and mechanical properties, including water absorption, thickness swelling, modulus of elasticity and bending strength. Thermogravimetric analysis of the recycled ABS edge-banding material and qualitative optical microscopy of the board surfaces were used to support, but not independently prove, the interpretation of the composite structure. The recycled ABS waste enabled the formation of compact boards, with density exerting the strongest influence on water resistance and bending performance. The regression models indicated a balanced region at 21.84 wt.% wood fibers and 1134 kg·m⁻³, corresponding to predicted water absorption of 1.62%, thickness swelling of 3.22%, modulus of elasticity of 2931 N·mm⁻² and bending strength of 22.20 N·mm⁻². Optical microscopy suggested a more continuous ABS-rich surface in the most homogeneous specimens, whereas local accumulations of fine particles and areas of limited polymer coverage were observed on the opposite surface. These findings demonstrate the potential of recycled ABS edge-banding waste for wood–polymer board production, while indicating that additional feedstock cleaning and sieving should be investigated in subsequent work to improve furnish uniformity and structural homogeneity. Full article

Flow-cell ultrasonication of gelatinized rice flour slurries alters cultivar-dependent water solubility, viscosity, and retrogradation of pregelatinized rice flour, properties important for plant-based beverages and convenience foods. We tested whether cultivar-level composition descriptors, amylose, protein, and fiber, can represent cultivar-associated variation in ultrasonication responses while separating process-only prediction, within-domain cultivar representation, and unseen-cultivar transfer. Six rice cultivars were processed across nine amplitude-time combinations and two slurry concentrations. Water solubility index, apparent viscosity at a shear rate of 50 s⁻¹, and setback viscosity were modeled using ElasticNet, partial least squares regression, support vector regression, random forest, and extreme gradient boosting. Three input formulations were compared: process variables alone, process variables plus composition descriptors, and process variables plus cultivar identity. Repeated nested group cross-validation showed insufficient process-only prediction and substantial improvement from composition descriptors. Within-domain validation showed comparable composition-descriptor and cultivar-identity performance under nonlinear algorithms. However, because cultivar identity is undefined for absent cultivars, leave-one-cultivar-out transfer of the composition-descriptor model remained uncertain. Cross-fitted Shapley additive explanations showed predictions used process and composition variables. For the validated cultivar-process domain, this approach can screen cultivar-process combinations for beverage and convenience-food applications, but replacing categorical source identifiers with continuous descriptors requires explicit transfer validation. Full article

Lightweight polymer composites with effective electromagnetic interference (EMI) shielding are of increasing interest for advanced electronic and aerospace applications; however, conventional glass fiber-reinforced polymers (GFRPs) exhibit inherently low electrical conductivity, limiting their shielding performance. In this study, a hierarchical hybrid conductive architecture was developed by integrating graphene-coated multiaxial glass fiber fabrics with carbon black (CB)-reinforced epoxy matrices to enhance EMI shielding behavior in the X-band (8–12 GHz). Graphene coatings were deposited onto glass fibers via a surfactant-assisted ultrasonic dispersion method, while carbon black (0–1 wt.%) was incorporated into the epoxy matrix using ultrasonication-assisted mixing. Multilayer composites were fabricated using a vacuum bagging process. X-ray diffraction analysis revealed that the composites retained a predominantly amorphous epoxy/glass fiber matrix while exhibiting broad carbon-related diffraction features associated with disordered graphitic domains. Electrical conductivity measurements indicated that all composites remained in the insulating regime (~10⁻⁹ S/m), suggesting that a fully interconnected conductive network was not established within the investigated filler range. Despite the absence of a continuous conductive network, measurable EMI shielding performance was achieved. The composite containing 0.25 wt.% CB exhibited the highest shielding effectiveness, reaching approximately 12 dB at ~11.2 GHz. Analysis of the shielding contributions showed that absorption contributions (SEA) were consistently higher than reflection contributions (SER) across the studied frequency range. Morphological observations revealed that well-dispersed CB at low loading facilitated the formation of localized conductive domains that may contribute to tunneling-assisted polarization and interfacial charge accumulation. At higher CB contents, particle agglomeration reduced dispersion quality and limited effective pathway formation, while dynamic mechanical analysis indicated enhanced stiffness at low CB loading. FTIR results confirmed the absence of new chemical bonding, indicating that CB acts as a physically dispersed conductive filler. Overall, the results show that effective EMI shielding can be achieved in electrically insulating composites through the combined effect of hierarchical structural design and localized conductive features. This approach provides a practical pathway for developing lightweight EMI shielding materials with controlled filler loading and preserved structural integrity for aerospace and electronic applications. Full article

Fused deposition modeling (FDM) provides a flexible manufacturing route for continuous fiber-reinforced thermoplastic composites, but weak interlaminar bonding and the trade-off between load-bearing capacity and deformation capability still limit their structural applications. In this study, multi-scale carbon/Kevlar fiber hybridization was introduced into acrylonitrile butadiene styrene (ABS)-based composites by combining continuous carbon fiber (CCF) or continuous Kevlar fiber (CKF) with short carbon fiber-filled ABS (ABS/SCF) or short Kevlar fiber-filled ABS (ABS/SKF). Four hybrid configurations and two continuous-fiber baseline composites were fabricated by FDM and evaluated through three-point bending tests, floating roller peel tests, peeled-surface SEM observations, and Rule-of-Mixtures-based hybrid effect analysis. The flexural results showed that short-fiber-filled matrices improved the flexural properties of both CCF- and CKF-based composites, but the degree of improvement depended on the fiber combination. Among the investigated configurations, CCF + ABS/SCF exhibited the highest flexural modulus and strength, which were 34.31% and 27.26% higher than those of CCF + ABS, respectively. For the CKF-based composites, CKF + ABS/SCF increased the flexural modulus and strength by 31.51% and 26.78%, compared with CKF + ABS, while maintaining the progressive deformation behavior associated with Kevlar reinforcement. The peel results showed that all hybrid composites had higher interlaminar peel resistance than their corresponding baselines, with increases ranging from 18.66% to 54.42%. The peeled-surface SEM observations indicated that the short-fiber-filled matrices changed the crack-propagation features, with more matrix tearing, fiber pull-out, and irregular peeling areas. The RoM-based comparison showed that the measured flexural properties of all hybrid configurations were higher than the corresponding RoM reference values. Overall, CCF + ABS/SCF was more suitable for improving stiffness and load-bearing capacity, whereas CKF + ABS/SCF showed a more balanced response in terms of flexural performance, interlaminar peel resistance, and progressive deformation behavior. Full article

3D-printed continuous carbon fiber-reinforced polylactic acid (CF/PLA) composites combine the high load-bearing capability of continuous fibers with the structural design freedom of additive manufacturing, showing broad application prospects in lightweight complex structures. However, the chemically inert surface of carbon fibers and their insufficient interfacial compatibility with the PLA matrix lead to inefficient interfacial load transfer, thereby limiting the mechanical performance of the composites. In this study, a waterborne polyurethane (WPU)-based sizing treatment was applied to carbon fibers to enhance the fiber–matrix interface of 3D-printed continuous CF/PLA composites. The WPU sizing layer increased fiber-bundle cohesion and introduced a transition region between CF and PLA through possible hydrogen bonding, dipolar interactions, and physical adhesion. When the nominal WPU concentration was 5 wt%, the apparent interfacial shear strength reached 1.31 MPa, representing an improvement of approximately 65% compared with ACF/PLA. The three-point flexural strength reached 69.76 MPa, which was 55.3% higher than that of the ACF/PLA composite. These results indicate that WPU sizing is an effective and scalable interfacial regulation strategy for improving the mechanical properties of 3D-printed continuous CF/PLA composites. Full article

Apple pomace is a widely available food processing by-product that has attracted increasing attention in circular and resource-efficient food systems for its potential in value-added food applications. The use of apple pomace in ready-to-eat (RTE) plant-based meat analogs represents a promising pathway. Unlike plant-based meats intended for cooking, RTE systems impose stricter constraints on structural stability, water retention, flavor integrity, and safety under cold chain conditions. Within this framework, apple pomace represents a compositionally complex material with both opportunities and constraints. This review examines how apple pomace and its derived ingredients can be utilized in RTE plant-based meat analogs, with particular attention to the distinct structural and functional requirements of minced-type and whole-cut products. Current evidence indicates that direct incorporation is more feasible for minced systems, where apple pomace fiber and pectin can support water retention, binding, and refrigerated slice stability when particle size, hydration, and sensory limits are controlled. By contrast, whole-cut applications are more likely to require fractionation, selective extraction, or additional structuring because particulate heterogeneity may disrupt continuous phase integrity and anisotropic structure formation. The review further identifies the main barriers to industrial translation, including water management under refrigerated conditions, flavor and color deviations, challenges in raw material standardization, and techno-economic constraints related to dewatering, processing intensity, and quality control. Overall, this review indicates that apple pomace can function as a technically relevant ingredient in RTE plant-based meat analogs. Its successful implementation depends on converting compositional complexity into predictable functionality through raw material standardization, controlled fraction use, food safety verification, and economically viable processing. In this way, sustainability-driven valorization can be better aligned with the practical requirements of industrial food production. Full article

The application of continuous carbon fiber (CCF) can reinforce the mechanical properties of 3D-printed parts, but the effect of reinforcement layer distribution on composite performance remains unclear. This study investigates the effect of concentrated and separated distributions of CCF layers with different numbers of reinforcement layers. Tensile and flexural tests are conducted in accordance with ASTM D5083 and ASTM D790, respectively. Under the conditions of a solid-filled matrix (Onyx) and 0° CCF deposition, both concentrated and separated CCF layers improve several mechanical properties. Compared with pure Onyx, one-layer CCF increases the tensile modulus by about six times and more than doubles the tensile strength. Increasing the CCF volume leads to further increases in these properties. With concentrated three-layer CCF, the tensile modulus and tensile strength reach 7.153 ± 0.090 GPa and 109.045 ± 5.124 MPa, respectively. For flexural properties, separated two- and three-layer CCFs significantly improve the tangent modulus of elasticity from 0.467 ± 0.106 GPa for pure Onyx to 2.246 ± 0.333 GPa and 3.394 ± 0.081 GPa, respectively. This study also compares the tensile and flexural strength-to-weight ratio of all specimen groups and analyzes the failure mechanisms based on macroscopic fracture appearance. The results can provide guidance for selecting appropriate CCF layer distribution strategies to reinforce composites in different applications. Full article

In this study, Fe₇₀Ni₃₀ metal was deposited onto continuous glass fiber composites via magnetron sputtering, followed by surface coating with SiO₂. The effects of key process parameters-including Fe₇₀Ni₃₀ sputtering duration (2, 5, 10, 20, and 30 min) and SiO₂ surface coating-on the electromagnetic properties and microwave absorption performance of the materials were systematically investigated. Scanning electron microscopy (SEM) characterization revealed that as sputtering time increased, the metal coating evolved from discrete small particles into a continuous film. Cross-sectional SEM analysis further demonstrated the formation of a bilayer structure after SiO₂ introduction. X-ray diffraction (XRD) patterns confirmed the presence of diffraction peaks corresponding to the Fe₇₀Ni₃₀ alloy solid solution. Electromagnetic parameter measurements indicated that the influence of sputtering time on electromagnetic properties was primarily pronounced during the metal layer growth stage; once a continuous film was formed, the variation in electromagnetic parameters diminished. Concurrently, the SiO₂ coating exhibited a significant regulatory effect on dielectric parameters. Reflection coefficient calculations showed that the optimal absorption thickness for the single-layer material ranged from 2.5 to 3.0 mm, with the absorption peak shifting toward lower frequencies as thickness increased. However, the effective absorption bandwidth (EAB) was only 3–5 GHz, failing to meet wideband requirements. In contrast, the three-layer composite structure (total thickness: 3.8 mm) optimized via genetic algorithm achieved impedance gradient and loss synergy, expanding the EBW (R < −10 dB) from 4.8 GHz (single layer) to 10 GHz (8–18.0 GHz)-a substantial improvement over the single-layer configuration. This work provides experimental evidence and technical support for the structural design and process optimization of lightweight, high-efficiency, wideband microwave-absorbing materials. Full article

There is a lack of knowledge concerning the interlaminar fracture toughness of 3D-printed composite materials using both commercial filament composites and fused deposition modeling (FDM) technology from Markforged^®. In this investigation, additive manufacturing (AM) continuous fiber-reinforced thermoplastic (cFRT) specimens have been tested to characterize the initiation and propagation of interlaminar fracture toughness in mode I (G_I). Unidirectional glass fiber (GF)-reinforced polyamide 6 (PA) laminates were characterized by means of the double cantilever beam (DCB) test. These specimens were manufactured using a MarkTwo^® printer and tested without doublers, following a laminate configuration selected according to appropriate experimental findings reported in the state of the art, ensuring reliable fracture characterization. The experimental results exhibited repeatability and strong agreement between the modified compliance calibration (MCC) and modified beam theory (MBT) reduction methods. The resistance curve (R-curve) indicated a progressive increase in fracture resistance during crack propagation. To analyze the experienced failure mechanism during testing, the fracture surfaces of representative post-mortem DCB specimens were observed using a scanning electron microscope (SEM), revealing characteristic morphological features at two magnification levels. Moreover, representative cross-sections of the tested DCB specimens were electronically observed to analyze the interlaminar morphologies, showing an irregular and random distribution of the matrix, fiber, and voids between consecutive plies and adjacent deposited rasters. Compared with previously reported Markforged^® continuous fiber-reinforced systems, the GF/PA composite material exhibited intermediate initiation fracture toughness but lower propagation toughness. This study contributes to filling the existing gap in fracture toughness data for glass fiber-reinforced additively manufactured composites. Full article

Pultrusion is an efficient continuous manufacturing process for fiber-reinforced polymer (FRP) composites, but conventional open-bath impregnation has limitations such as resin exposure, quality variation, and resin loss. To overcome these limitations, closed-injection pultrusion (CIP) and short-pot-life resin systems have recently been introduced. However, the effects of processing variables on the quality and properties of composites manufactured using such resin systems have not been fully clarified. In this study, the effects of resin viscosity and pulling speed on the quality and mechanical properties of carbon FRP (CFRP) and glass FRP (GFRP) composites manufactured by CIP were investigated. CFRP and GFRP composites were fabricated at resin temperatures of 30 and 40 °C and pulling speeds of 300, 400, and 500 mm/min. The manufactured composites were evaluated in terms of void content, microstructure, hardness, and tensile properties. The results showed that increasing pulling speed increased void content and promoted macrovoids and locally poor impregnation, whereas the influence of resin temperature was relatively limited. Hardness, tensile strength, and elastic modulus decreased as pulling speed increased. These results demonstrate that CFRP and GFRP composites can be successfully manufactured by CIP using short-pot-life resin systems, and that precise control of resin viscosity and pulling speed is essential for achieving high quality and mechanical performance. Full article

Smart manufacturing, Industry 4.0, and cyber-physical systems (CPSs) require sensing architectures capable of resolving both spatially distributed asset behavior and highly localized process states. This review examines optical fiber sensors (OFSs) and integrated photonic sensors for industrial monitoring through a deployment-oriented, multi-scale perspective. The discussion covers five major application regimes: continuous infrastructure surveillance, structural health monitoring (SHM) of load-bearing composites, dynamic condition monitoring of machinery, in situ observability in advanced manufacturing, and localized chemical or gas sensing. Extended fiber-optic networks, including distributed fiber-optic sensing (DFOS) based on Rayleigh, Raman, and Brillouin scattering, together with multiplexed fiber Bragg grating (FBG) sensors, provide passive, embeddable, and remotely interrogated monitoring for large-scale assets and harsh environments. Photonic integrated circuits (PICs) shift transduction to compact node-level devices for localized thermal, mechanical, refractive-index, absorption, vibration, and inertial measurements, while plasmonic and dielectric nanophotonic sensors extend optical monitoring toward surface-selective and chemically specific detection. Across these platforms, digital signal processing (DSP), machine learning (ML), sensor fusion, and digital-twin (DT) coupling are treated as artificial-intelligence-enabled (AI-enabled) layers for signal recovery, inverse mapping, uncertainty reduction, and predictive maintenance. The review argues that scalable industrial adoption is less limited by sensing physics than by the complete deployment chain: packaging, fiber–chip interfacing, calibration stability, interrogation robustness, and AI-enabled data interpretation. This manuscript is structured as a deployment-oriented narrative review of optical fiber and integrated photonic sensors for industrial monitoring and smart manufacturing. Full article

Microplastic contamination in wetland ecosystems is an escalating environmental threat, compromising ecosystem services, biogeochemical cycling and biodiversity conservation. This study assessed the occurrence, distribution and physicochemical characteristics of microplastics in the Ramsar-designated Pallikaranai wetland, southern India. Six representative subsamples were collected from spatially distinct locations and analyzed using density separation, followed by polymer identification via Raman spectroscopy and energy-dispersive X-ray spectroscopy (EDS). Microplastics were ubiquitously detected across both sediment and water matrices, with significantly higher abundances in sediments, indicating their role as a major sink. The dominant polymer types, polyethylene (PE), polypropylene (PP) and polystyrene (PS), along with prevalent morphotypes such as fragments, fibers, beads and foams, reflect diverse and persistent anthropogenic inputs. The compositional profile strongly implicates mismanaged domestic and urban waste as the primary source. The widespread presence and accumulation of microplastics in this ecologically sensitive wetland raise concerns over potential impacts on trophic interactions, habitat quality and long-term ecosystem resilience. These findings underscore the urgent need for targeted waste management strategies, pollution mitigation frameworks and continuous monitoring to safeguard the ecological integrity of the Pallikaranai wetland and similar Ramsar-listed ecosystems. Full article

Radar technology in the microwave and millimeter-wave frequency range is the subject of current research for structural health monitoring of composite materials, e.g., damage detection in wind turbine blades. Performance assessment, enabling widespread practical application of this promising and non-contact sensing approach, can be realized via probability of detection (POD) theory, which is a statistical method for determining the detectability of damage through response metrics as a function of flaw size. This paper deals with the experimental investigation of a delamination model represented by two parallel glass fiber reinforced polymer plates separated from each other from $0\mathrm{mm}$ to $1\mathrm{mm}$ in steps of $0.01\mathrm{mm}$. Experimental studies with a frequency modulated continuous wave radar are performed under laboratory conditions in the frequency range from $57GHz$ to $65GHz$. The signal response is represented by two damage indicators (DIs), according to the root mean square deviation and Mahalanobis distance. Since the reflection of electromagnetic waves exhibits a nonlinear behavior, this also implies a nonlinear response in the DI characteristic. The novelties in this work are the successful implementation of a nonlinear regression model, combined with an optimal threshold decision through receiver operating characteristic curves for a high-resolution POD representation. The POD with $95\%$ confidence bounds indicates the flaw size at which the delamination can be detected reliably. Depending on the radar distance in experimental studies, the binary structural condition (damaged or undamaged) was correctly assessed from $95\%$ to $100\%$. The minimum detectable size ranges from $0.01\mathrm{mm}$ to $0.08\mathrm{mm}$. Full article

This study evaluates the industrial-scale feasibility of injection moulding of a recycled polypropylene composite reinforced with recycled fibers derived from an industrial waste stream. Although previous laboratory-scale research has demonstrated the potential of natural fiber-reinforced thermoplastics, their large-scale industrial implementation remains limited due to uncertainties related to processability, reproducibility, and manufacturing robustness. In this work, the composite material is validated through injection moulding trials carried out in four independent industrial companies located in Andalusia (Spain) and three industrial case studies across different industrial sectors in Slovenia, operating under real production conditions. The extrusion process was characterized in terms of process stability, confirming continuous operation with automated dosing and stable material flow without interruptions under industrial conditions. Injection processing parameters, cycle stability, part quality, and defect formations are also considered important when assessing the manufacturing feasibility. The multi-site validation approach enables the evaluation of reproducibility across different injection moulding systems and mould geometries, providing critical insights into the scalability and technological readiness level of recycled natural fiber-reinforced polypropylene composites. Although direct energy consumption measurements were not systematically recorded, the observed processing stability and cycle repeatability indicate a consistent and energy-efficient operation under industrial processing conditions. The results contribute to bridging the gap between laboratory-scale material development and real industrial implementation. Full article

This study investigates the effect of 3-glycidoxypropyltrimethoxysilane (GPTMS) concentration on the mechanical, interfacial, and fracture behavior of epoxy/microfibrillated cellulose (MFC) composites derived from oil palm empty fruit bunch (OPEFB). GPTMS was incorporated at 1, 3, and 5 Phr to improve compatibility between hydrophilic MFC and the hydrophobic epoxy matrix. Mechanical testing revealed that GPTMS concentration significantly influenced composite performance in a concentration-dependent manner, with 1 Phr GPTMS providing the most balanced reinforcement. At this concentration, tensile strength increased by 14.5% from 32.88 ± 3.61 MPa to 37.65 ± 1.42 MPa, while flexural strength improved by 5.55% from 70.24 ± 5.30 MPa to 74.14 ± 4.10 MPa compared with the unmodified composite. Tensile modulus also increased from 2.07 ± 0.06 GPa to 2.21 ± 0.16 GPa, accompanied by improved flexural modulus from 2.39 ± 0.12 GPa to 2.47 ± 0.21 GPa. SEM analysis revealed that the optimized formulation promoted more uniform MFC dispersion, improved interfacial integrity, reduced void formation, and enhanced fracture resistance through tortuous crack propagation, localized radial crack branching, and matrix tearing. In contrast, higher GPTMS concentrations (3 and 5 Phr) reduced mechanical efficiency, with flexural strength declining to 65.27 ± 5.33 MPa and 66.16 ± 4.23 MPa, respectively, due to increased fiber pull-out, interfacial heterogeneity, and more continuous crack propagation. FTIR analysis suggested possible silane-related interfacial modifications consistent with GPTMS incorporation, although these findings are interpreted as supportive rather than definitive evidence of grafting. Overall, the results demonstrate that moderate GPTMS incorporation (1 Phr) is the optimum strategy for enhancing epoxy/MFC composite performance, offering a practical pathway for developing sustainable lightweight bio-based composites with balanced strength, stiffness, and fracture resistance. This research contributes to SDG 12 (Responsible Consumption and Production) by promoting sustainable utilization of oil palm biomass waste for advanced engineering materials. Full article