Search Results (268)

End-of-life (EoL) continuous glass fibre-reinforced polyamide 6 composites (cGF/PA6) are commonly recycled by shredding and milling, followed by injection moulding, often resulting in lower mechanical properties of second-generation products, primarily due to fibre length reduction. This study investigates the thermomechanical reprocessing of cGF/PA6 laminates via compression moulding, aiming to retain maximum mechanical performance by preserving the fibre length. Two types of 2/2 twill glass fibre-reinforced anionically polymerised polyamide 6 laminates (cGF/APA6), with either a reactive sizing agent (RS) or a non-reactive sizing agent (nRS), were reprocessed at two different temperatures, i.e., at 180 °C (between the glass transition temperature (Tg) and the melting temperature (Tm) of PA6) and 230 °C (above the melting temperature (Tm) of PA6). The influence of reprocessing on matrix crystallinity, thermomechanical properties, microstructure, and flexural performance was investigated. The results revealed that reprocessing at both temperatures led to an improvement in matrix crystallinity, retention of the desirable α-crystalline phases, and an elevated T_g (glass transition temperature) in both reprocessed laminates. Additionally, reprocessing at 180 °C maintained the flexural performance in both, whereas reprocessing at 230 °C led to nearly 20% improvement in flexural strength for the RS laminate. The microstructural analysis of the failed flexural specimens showed matrix-coated fibre surfaces, highlighting retained fibre–matrix adhesion. Overall, the results offer insights into the potential of compression moulding as a viable alternative for recycling cGF/APA6 laminates. Full article

Reinforcing PLA composites with natural fibres is a prominent strategy for improving PLA’s properties while benefiting from its intrinsic biodegradation. However, these composites may be susceptible to an inefficient stress-transferring process due to the weak intermolecular interactions between PLA and natural fibres. A well-known practice is to incorporate coupling agents to improve polymer–fibre adhesion, such as carboxylic acids (CAs) and grafted copolymers. CAs are a more affordable and biodegradable option for improving PLA/natural fibre interface strength, resulting in a material with superior mechanical and thermal properties. In this context, this research discusses the potential use of mono (C6 and C8) and di (CC6 and CC8) carboxylic acids as coupling agents in PLA/pecan nutshells (PN) composites. PLA/PN composites with four different CAs were processed in a twin-screw extruder and subsequently injection moulded. The results indicated an increase in the flexural strength of the PLA due to the presence of PN in the neat composite. The use of CAs increased the storage modulus of PLA/PN composites, while C6 and CC8 reduced the PLA composite tan δ peak height. The PLA’s T_g in PLA/PN composite shifted to lower temperatures after the incorporation of CAs while increasing the PLA crystallinity degree. These results strongly suggested that besides acting as efficient coupling agents, these acids also exerted roles as nucleating agents and plasticisers. Full article

Car interior design should evoke emotions, offer comfort, convey safety and at the same time project the brand identity of the car manufacturer. Lighting is used to address these functions. Modules required for automotive interior lighting often feature injection-moulded (IM) light guides, whereas woven fabrics with polymer optical fibres (POFs) offer certain technological advantages and show first-series applications in cars. In the future, car interior illumination will become even more important in the wake of megatrends such as autonomous driving. Since the increase in deployment of these technologies facilitates a need for an economical comparison, this paper aims to deliver a cost-driven approach to fulfil the aforementioned objective. Therefore, the cost structures of the supply chains for an IM-based and a POF-based illumination module are analysed. The employed research methodologies include an activity-based costing approach for which the data is collected via document analysis and guideline-based expert interviews. To account for data uncertainty, Monte Carlo simulations are conducted. POF-based lighting modules have lower initial costs due to continuous fibre production and weaving processes, but are associated with higher unit costs. This is caused by the discontinuous assembly of the rolled woven fabric which allows postponement strategies. The development costs of the mould generate high initial costs for IM light guides, which makes them beneficial only for high quantities of produced light guides. For the selected scenario, the POF-based module’s self-costs are 11.05 EUR/unit whereas the IM module’s self-costs are 14,19 EUR/unit. While the cost structures are relatively independent from the selected scenario, the actual self-costs are highly dependent on boundary conditions such as production volume. Full article

The burgeoning crisis of plastic waste accumulation necessitates innovative approaches towards sustainable packaging solutions. Polylactic acid (PLA), a leading biopolymer, emerges as a promising candidate in this realm, especially for environmentally friendly packaging. PLA is renowned for its compostable properties, offering a strategic avenue to mitigate plastic waste. However, its dependency on specific industrial composting conditions, characterized by elevated temperatures, humidity, and thermophilic microbes, limits its utility for household composting. This study aims to bridge the research gap in PLA’s recyclability and explore its feasibility in mechanical recycling processes. The research focuses on assessing the mechanical characteristics of PLA and PLA-based composites post-recycling. Specifically, we examined the effects of two extrusion methods—conical and parallel—on PLA and its composites containing 20 wt.% basalt fibers (BF). The recycling process encompassed repeated cycles of hot melt extrusion (HME), followed by mechanical grinding to produce granules. These granules were then subjected to injection moulding (IM) after 1, 3 and 5 recycling cycles. The tensile properties of the resulting IM-produced bars provided insights into the material’s durability and stability. The findings reveal that both PLA and PLA/BF composites retain their mechanical integrity through up to 5 cycles of mechanical recycling. This resilience underscores PLA’s potential for integration into existing recycling streams, addressing the dual challenges of environmental sustainability and waste management. The study contributes to the broader understanding of PLA’s lifecycle and opens new possibilities for its application in eco-friendly packaging, beyond the limits of composting. The implications of these findings extend towards enhancing the circularity of biopolymers and reducing the environmental footprint of plastic packaging. Full article

The recycling of plastics collected from household waste to produce post-consumer recycled (PCR) materials is a critical step of sustainable waste management. However, the processing of PCR materials presents unique challenges, particularly in the context of seasonal input stream fluctuations and resulting PCR material composition variations. Within this paper, the influence of batch-to-batch fluctuations on the processing stability and product properties of high-density polyethylene (HDPE) PCR from the German municipal waste system is analysed. It examines how variations in batch composition affect key parameters such as processing data (injection pressure, torque), mechanical properties (tensile strength, E-modulus, impact strength), and product quality (gel formation, part dimensions, part weight). Therefore, six consecutive household HDPE PCR material batches are analysed regarding their composition, contaminations, and rheological characteristics through ashing, differential scanning calorimetry, high-temperature gel permeation chromatography, and high-pressure capillary rheometry. The batches are then processed using blown- and cast-film extrusion as well as injection moulding, and the resulting process stability and product quality are analysed. The results show a strong correlation between thermal properties, such as crystallisation enthalpy, molecular weight, polypropylene (PP) content, varying batch viscosities, and changes in processing data as well as the resulting product properties. Full article

The rapid advancement of sustainable materials has driven the need for high-performance polymer nanocomposites with superior mechanical, thermal, and structural properties. In this study, a novel RPET/PA-11/Joncryl^® nanocomposite reinforced with halloysite nanotubes (HNTs) is developed for the first time, marking a significant breakthrough in polymer engineering. Six different proportions of HNT (0, 1, 2, 3, 4, and 5 phr) are introduced to the blend of rPET/PA-11/Joncryl^® through a twin-screw extruder and injection moulding machine. The incorporation of HNTs into the RPET/PA-11 matrix, coupled with Joncryl^® as a compatibilizer, results in a synergistic enhancement of material properties through improved interfacial adhesion, load transfer efficiency, and nanoscale reinforcement. Comprehensive characterization reveals that the optimal formulation with 2 phr HNT (NCS-H2) achieves remarkable improvements in tensile strength (56.14 MPa), flexural strength (68.34 MPa), and Young’s modulus (895 MPa), far exceeding conventional polymer blends. Impact resistance reaches 243.46 J/m, demonstrating exceptional energy absorption and fracture toughness. Thermal analysis confirms enhanced stability, with an onset degradation temperature of 370 °C, attributing the improvement to effective matrix–filler interactions and restricted chain mobility. Morphological analysis through FESEM validates uniform HNT dispersion at optimal loading, eliminating agglomeration-induced stress concentrators and reinforcing the polymer network. The pioneering integration of HNT into RPET/PA-11/Joncryl^® nanocomposites not only bridges a critical gap in sustainable polymers but also establishes a new benchmark for polymer nanocomposites. This work presents an eco-friendly solution for engineering applications, offering mechanical robustness, thermal stability, and recyclability. The results form the basis for next-generation high-performance materials for industrial use in automotive, aerospace, and high-strength structural applications. Full article

In addition to ensuring the functionality of objects used in the household, transport or industry at large, applied design focuses on aesthetic qualities related to the external form and condition of a surface. At the same time, there is a trend for plastic, rubber or aluminium objects made by moulding (both injection and casting) to look as if they were made of natural materials. This effect is ensured by properly designed and manufactured surface textures in the mould seats. However, the working surfaces of the moulds often corrode as a result of inadequate maintenance and storage. The aim of this study was to find out how popular agents on the market dedicated to corrosion product removal would change the surface geometrical texture. During the prepared experimental plan, it was also decided to investigate the properties in this respect of one of the popular drinks (i.e., cola) which is sometimes used in workshop practice as an alternative corrosion product removal agent. Based on the results of the study, conclusions were drawn about the short- and long-term effects of the corrosion product removal agents. Full article

This study explores the development of polypropylene (PP) compound recipes using analytical models (AM) combined with genetic algorithms (GAs). A talcum-filled PP compound, commonly utilised in injection moulding for packaging applications, served as a reference material, with shear viscosity, tensile modulus, and impact strength selected as target properties for replication. The AM were adapted and fitted to a dataset of 52 compounds, achieving high predictive accuracy for shear viscosity and tensile modulus, while impact strength proved more challenging due to its inherent variability. Three recipes were generated using GA under predefined material constraints. Recipe 1 aimed to replicate all three target properties, achieving a balanced compromise with maximum deviations of 13.14% for tensile modulus and 12.37% for impact strength while closely matching shear viscosity (maximum 9.8% deviation). Recipes 2 and 3, focused solely on matching shear viscosity and impact strength, demonstrated exceptional accuracy for shear viscosity, with Recipe 2 achieving near-perfect alignment (2.5% deviation). However, neither recipe approached the tensile modulus target due to material limitations. The findings demonstrate the effectiveness of combining AM with GA for designing alternative formulations, emphasising the importance of realistic targets and material constraints. This methodology is highly adaptable, allowing for the inclusion of additional optimisation criteria such as cost or sustainability. Future work will explore broader material sets and properties, extending the framework’s applicability to technical polymers and diverse industrial applications. Full article

This study investigates the development of sustainable nanocomposites using recycled polyethylene terephthalate (RPET) and polyamide 11 (PA-11) blends reinforced with graphene nanoplatelets (GNPs). RPET/PA-11 blends were compatibilized with 2 phr Joncryl^® and processed using melt blending followed by injection moulding. The effects of varying GNP contents (1–4 phr) on mechanical, thermal, and flame-retardant properties were analysed. The nanocomposite with 1 phr GNPs exhibited an optimal balance of mechanical, flame-retardant, and thermal properties, along with improved dispersion compared to higher GNP loadings. Higher GNP concentrations led to increased stiffness but also promoted agglomeration, which negatively impacted tensile and impact strength. Thermal analysis revealed that GNPs influenced the cold crystallization behaviour of RPET, while the TGA results indicated a moderate enhancement in thermal stability. The maximum degradation temperature (T_max) increased from 410.38 °C to 430.06 °C with 1 phr GNPs but declined at higher loadings. Similarly, flammability tests showed an improvement in the limiting oxygen index (LOI) from 19 to 24. Morphological analysis confirmed that GNPs facilitated PA-11 dispersion within the RPET matrix, particularly at lower GNP concentrations (1 phr). These findings highlight the potential of RPET/PA-11/GNP nanocomposites for multifunctional applications, providing an optimal balance between mechanical performance, thermal stability, and flame resistance. This research highlights the synergistic effect of GNPs in achieving sustainable, high-performance materials, addressing the challenges of plastic waste management and the need for eco-friendly engineering solutions for industries such as automotive, packaging, and construction. Full article

This study explores the mechanical performance of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) filaments fabricated using fused filament fabrication (FFF), Arburg plastic freeforming (APF), and injection moulding (IM). A series of controlled experiments, including differential scanning calorimetry (DSC), scanning electron microscopy (SEM), dynamic mechanical thermal analysis (DMA), and mechanical tests, were conducted to evaluate the material’s mechanical, thermal, and chemical properties. The results highlight the influence of process parameters and material choice on the mechanical properties of PC/ABS components. The FFF samples exhibited the highest impact strength (up to 28.82 kJ/m²), attributed to porosity acting as a stress absorber under impact load. However, this same porosity led to a 9.14% and 19.27% reduction in flexural and tensile strength, respectively, compared to the APF samples, where stress concentration effects were more pronounced under flexural loads. APF’s mechanical properties were comparable to those of IM, with the process achieving the highest tensile strength, highlighting its potential for producing robust PC/ABS samples. This study aims to provide valuable insight into the selection of additive manufacturing (AM) processes for PC/ABS components. Full article

Additive manufacturing (AM) has swiftly emerged as a substitute for conventional methods such as machining and injection moulding. Its appeal is attributed to accelerated prototyping, improved sustainability, and the capacity to fabricate intricate shapes. Nonetheless, the size constraints of additive manufacturing components require the assembly of smaller 3D-printed elements to create larger structures. This study investigates the tensile properties of scarf joints (SJs) created from several polymers, including ABS, PETG, and PLA, adhered with Araldite^® 2015 and Sikaforce^® 7752 adhesives. The characteristics of the adherends were assessed prior to examining the adhesive efficacy in the SJ configuration. Experimental evaluations quantified failure modes, joint strength, assembly stiffness, and energy at failure, comparing findings with predictions from a cohesive zone model (CZM). The objective was to determine the ideal combination of materials and adhesives for enhanced joint performance. Results indicated that joint performance is greatly affected by the adherend material, adhesive selection, and scarf angle. PLA and Araldite^® 2015 typically exhibited optimal strength and stiffness, but Sikaforce^® 7752 demonstrated enhanced energy absorption for extended bonding lengths. Full article

In this work, by-products from insect farming valorisation are proposed as filler in biocomposite production, with relevant biodegradation in compost and valuable thermal and mechanical properties. Thus, we report on the preparation, properties, and biodegradability in compost of composites based on Poly(butylene succinate-co-adipate) (PBSA) and Poly(3-hydroxybutyrate-3-hydroxyvalerate) (PHB-HV) (70/30% by weight as a polymeric matrix, with filler from insect exoskeleton (I) up to 15% by weight in the 85% by weight of polymeric matrix. The insect biomass was a by-product obtained from grinding the insect’s post-protein extraction dry exoskeleton. The composites were produced by melt extrusion and characterised in terms of processability, thermal stability, morphology, and mechanical properties to select formulations optimised for injection moulding processing. The optimised composites (PBSA/PHB-HV) with 15% by weight of filler were used to produce pots by injection moulding on an industrial scale extruder. Selected formulations were tested for biodegradability in compost, which evidenced the relevance of insect exoskeleton filler for meeting the requirements for the disintegration of rigid items. This paper presents a sustainable option for valorising the insect exoskeleton residue that remained after protein extraction for animal feed production and reducing the production cost of PBSA/PHB-HV-based composites without compromising the mechanical properties for application as rigid items in agriculture, all while promoting biodegradability in industrial compost. Full article

Wood–polymer composites and composites reinforced with natural and man-made cellulose fibres are being extensively used in the automotive and building industries. The main shortcoming of the former is their low-impact resistance and brittleness. The relatively high cost of natural and cellulose fibres is the limitation of the latter. This research uses a hybrid combination of wood flour and short man-made cellulose fibres to develop polypropylene composites for injection moulding that excel in mechanical characteristics and have low material cost. Both reinforcements are of wood origin. The synergistic hybrid effect of this combination of reinforcements helps to achieve their mechanical performance superior to that of wood–polymer composites at preserved low cost. The proposed Response Surface Methodology enables the calculation of necessary weight fractions of two reinforcements to achieve desired mechanical properties like strength, tensile, flexural modulus, and impact resistance. Full article

Allergens from pollen, mites, and moulds often sensitise patients simultaneously, posing challenges for developing stable and effective combination vaccines. Alternaria alternata, a major source of indoor and outdoor allergens, is strongly linked to asthma development and contains proteolytic enzymes that can degrade other allergens, potentially reducing vaccine efficacy. This study aimed to evaluate the safety, efficacy, and stability of polymerised A. alternata extracts (allergoids) compared to native extracts and their compatibility with pollen extracts (Phleum pratense). Allergoids were prepared using glutaraldehyde and characterised through SDS-PAGE, LC-MS/MS, NMR, and gas chromatography. Their immunogenicity and IgE-binding properties were assessed via Western blot and ELISA competition assays, while enzymatic activity was analysed using ApiZym kits. Mice immunisation experiments were conducted to evaluate antibody responses. Polymerised extracts exhibited reduced IgE-binding capacity while maintaining IgG-binding and immunogenicity. Mice immunised with allergoids generated antibodies that efficiently blocked IgE binding in allergic patients. Proteolytic activity was significantly reduced in allergoids, and pollen extracts remained stable when combined with them. These findings demonstrate that A. alternata allergoids are a safer, more stable alternative for immunotherapy, offering enhanced efficacy and reduced injections for polysensitised patients. This study provides critical insights for designing optimised combination vaccines. Full article

Additive manufacturing (AM) has revolutionised the production of customised components across industries such as the aerospace, automotive, healthcare, electronics, and renewable energy industries. Offering unmatched design freedom, reduced time-to-market, and minimised material waste, AM enables the fabrication of high-quality, customised products with greater sustainability compared to traditional methods like machining and injection moulding. Additionally, AM reduces energy consumption, resource requirements, and CO₂ emissions throughout a material’s lifecycle, aligning with global sustainability goals. This paper highlights insights into the sustainability of AM polymers, comparing bio-based and traditional polymers. Bio-based polymers exhibit lower carbon footprints during production but may face challenges in durability and mechanical performance. Conversely, traditional polymers, while more robust, require higher energy inputs and contribute to greater carbon emissions. Polymer composites tailored for AM further enhance material properties and support the development of innovative, eco-friendly solutions. This Special Issue brings together cutting-edge research on polymer composites in AM, focusing on processing techniques, microstructure–property relationships, mechanical performance, and sustainable manufacturing practices. These advancements underscore AM’s transformative potential to deliver versatile, high-performance solutions across diverse industries. Full article