Search Results (36)

Two-component micro-powder injection moulding (2C-μPIM) is a prospective approach for fabricating bi-material micro-components of stainless steel 316L (SS316L) and 3 mol% yttria-stabilised zirconia (3YSZ) at an appealing cost. However, the fundamental challenge lies in preventing the formation of large-scale cracks at the interface of two different materials during sintering. This study investigated how SS316L nanoparticles in bimodally configured SS316L powder that incorporated both nanoparticles and microparticles influenced the sintering of 2C-μPIM-processed miniature bi-materials made of bimodal SS316L and 3YSZ. In this study, feedstocks were developed by integrating monomodal (micro-sized) SS316L powder, three types of nano/micro-bimodal SS316L powders, and 3YSZ powder individually with palm stearin and low-density polyethylene binders. The results indicated that increasing the SS316L nanoparticle content to 45 vol.% caused a 19.5% increase in the critical powder loading in the bimodal SS316L powder as compared to that in the monomodal SS316L powder. The addition of SS316L nanoparticles increased the relative density and hardness of the sintered bi-materials, with the maximum values obtained being 96.8% and 1156.8 HV, respectively. Field emission scanning electron microscopy investigations revealed that adding 15 vol.% and 30 vol.% SS316L nanoparticle contents reduced interface cracks in bi-materials significantly, while 45 vol.% resulted in a crack-free interface. Full article

Fibre deformation (or shearing of yarns) can develop during the liquid moulding of composites due to injection pressures or polymerisation (cross-linking) reactions (e.g., chemical shrinkage). On that premise, this may also induce potential residual stress–strain, warpage, and design defects in the composite part. In this paper, a developed numerical framework is customised to analyse deformations and the residual stress–strain of fibre (at a micro-scale) and yarns (at a meso-scale) during a liquid composite moulding (LCM) process cycle (fill and cure stages). This is achieved by linking flow simulations (coupled filling–curing simulation) to a transient structural model using ANSYS software. This work develops advanced User-Defined Functions (UDFs) and User-Defined Scalers (UDSs) to enhance the commercial CFD code with extra models for chemorheology, cure kinetics, heat generation, and permeability. Such models will be hooked within the conservation equations in the thermo-chemo-flow model and hence reflected by the structural model. In doing so, the knowledge of permeability, polymerisation, rheology, and mechanical response can be digitally obtained for more coherent and optimised manufacturing processes of advanced composites. Full article

The fabrication of bi-material micro-components via two-component micro-powder injection moulding (2C-µPIM) from 3 mol% yttria-stabilised zirconia (3YSZ) and micro/nano bimodal stainless steel 316L (SS 316L) powders has received insufficient attention. Apart from this, retaining the bonding between ceramic and metal at different processing stages of 2C-µPIM is challenging. This study investigated the solvent and thermal debinding mechanisms of green bi-material micro-parts of 3YSZ and bimodal SS 316L without collapsing the ceramic/metal joining. In this research, feedstocks were prepared by integrating the powders individually with palm stearin and low-density polyethylene binders. The results demonstrated that during the solvent debinding process, the palm stearin removal rate in the bi-materials composed of 3YSZ and bimodally configured SS 316L feedstocks intensified with an increase in temperature. The establishment of interconnected pores in the solvent-debound components facilitated the thermal debinding process, which removed 99% of the binder system. Following sintering, the debound bi-materials exhibited a relative density of 95.3%. According to a study of the microstructures using field emission scanning electron microscopy, an adequate bond between 3YSZ and bimodal SS 316L was established in the micro-part after sintering. The bi-material sintered at 1350 °C had the highest hardness of 1017.4 HV along the joining region. Full article

Producing sustainable microfluidic devices on a large scale has become a trend in the biomedical field. However, the transition from laboratory prototyping to large-scale industrial production poses several challenges due to the gap between academia and industry. In this context, prototyping with a mass production approach could be the novel strategy necessary to bridge academic research to the market. Here, the performance of polymer inserts to produce PMMA microfluidic devices using the microinjection moulding process is presented. Inserts were fabricated with an additive manufacturing process: material jetting technology. The importance of the inserts’ orientation on the printing plate in order to produce samples with more uniform thickness and lower roughness has been demonstrated using a flat cavity insert. In addition, preliminary tests were carried out on microstructured inserts with inverted channels of various cross-section shapes (semi-circular or trapezoidal) and widths (200 or 300 µm) in order to investigate the microstructures’ resistance during the moulding cycles. The best geometry was found in the channel with the trapezoidal cross-section with a width equal to 300 µm. Finally, a preliminary microfluidic test was performed to demonstrate the devices’ workability. Full article

The Fresnel lens is an optical system consisting of a series of concentric diamond grooves. One surface of the lens is smooth, while the other is engraved with concentric circles of increasing size. Optical interference, diffraction, and sensitivity to the angle of incidence are used to design the microstructure on the lens surface. The imaging of the optical surface depends on its curvature. By reducing the thickness of the lens, light can still be focused at the same focal point as with a thicker lens. Previously, lenses, including Fresnel lenses, were made of glass due to material limitations. However, the traditional grinding and polishing methods for making Fresnel lenses were not only time-consuming, but also labour-intensive. As a result, costs were high. Later, a thermal pressing process using metal moulds was invented. However, the high surface tension of glass caused some detailed parts to be deformed during the pressing process, resulting in unsatisfactory Fresnel lens performance. In addition, the complex manufacturing process and unstable processing accuracy hindered mass production. This resulted in high prices and limited applications for Fresnel lenses. These factors prevented the widespread use of early Fresnel lenses. In contrast, polymer materials offer advantages, such as low density, light weight, high strength-to-weight ratios, and corrosion resistance. They are also cost effective and available in a wide range of grades. Polymer materials have gradually replaced optical glass and other materials in the manufacture of micro-optical lenses and other miniaturised devices. Therefore, this study focuses on investigating the manufacturing parameters of Fresnel lenses in the injection moulding process. We compare the quality of products obtained by two-stage injection moulding, injection compression moulding, and IMD (in-mould decoration) techniques. The results show that the optimal method is IMD, which reduces the nodal displacement on the Fresnel lens surface and improves the transmission performance. To achieve this, we first establish a Kriging model to correlate the process parameters with optimisation objectives, mapping the design parameters and optimisation objectives. Based on the Kriging model, we integrate the NSGA-II algorithm with the predictive model to obtain the Pareto optimal solutions. By analysing the Pareto frontier, we identify the best process parameters. Finally, it is determined that the average nodal displacement on the Fresnel surface is 0.393 mm, at a holding pressure of 320.35 MPa and a melt temperature of 251.40 °C. Combined with IMD technology, product testing shows a transmittance of 95.43% and an optimisation rate of 59.64%. Full article

Many of the carbon and natural fibres used in composite reinforcement have a non-circular cross section. Recently non-circular, or flat, cross section glass fibre products have become commercially available. This paper explores the potential effects that such non-circular fibre cross section shapes may have on the micromechanics of stress transfer at the composite fibre–matrix interface and the resulting changes in composite strength performance. Analytical modelling is used to show how the critical fibre length in composites with non-circular fibres is always less when compared to circular fibres with an equal cross-sectional area. This can result in significant changes to the strength performance of discontinuous fibre reinforced composites. Additionally, it is shown that the surface roughness found on natural and carbon fibres, many of which are also non-circular in cross section, can decrease the critical fibre length still further. These effects have important consequences for the use of single fibre micromechanical tests used for the characterisation of interfacial strength. Full article

When overmoulding optoelectronic devices with optical elements, precise alignment of the overmoulded part and the mould is of great importance. However, mould-integrated positioning sensors and actuators are not yet available as standard components. As a solution, we present a mould-integrated optical coherence tomography (OCT) device that is combined with a piezo-driven mechatronic actuator, which is capable of performing the necessary displacement correction. Because of the complex geometric structure optoelectronic devices may have, a 3D imaging method was preferable, so OCT was chosen. It is shown that the overall concept leads to sufficient alignment accuracy and, apart from compensating for the in-plane position error, provides valuable additional information about the sample both before and after the injection process. The increased alignment accuracy leads to better energy efficiency, improved overall performance and less scrap parts, and thus even a zero-waste production process might be feasible. Full article

Fenbendazole (FBZ) is a broad-spectrum anthelmintic administered orally to ruminants; nevertheless, its poor water solubility has been the main limitation to reaching satisfactory and sustained levels at the site of the target parasites. Hence, the exploitation of hot-melt extrusion (HME) and micro-injection moulding (µIM) for the manufacturing of extended-release tablets of plasticised solid dispersions of poly(ethylene oxide) (PEO)/polycaprolactone (PCL) and FBZ was investigated due to their unique suitability for semi-continuous manufacturing of pharmaceutical oral solid dosage forms. High-performance liquid chromatography (HPLC) analysis demonstrated a consistent and uniform drug content in the tablets. Thermal analysis using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) suggested the amorphous state of the active ingredient, which was endorsed by powder X-ray diffraction spectroscopy (pXRD). Fourier transform infrared spectroscopy (FTIR) analysis did not display any new peak indicative of either a chemical interaction or degradation. Scanning electron microscopy (SEM) images showed smoother surfaces and broader pores as we increased the PCL content. Electron-dispersive X-ray spectroscopy (EDX) revealed that the drug was homogeneously distributed within the polymeric matrices. Drug release studies attested that all moulded tablets of amorphous solid dispersions improved the drug solubility, with the PEO/PCL blend–based matrices showing drug release by Korsmeyer–Peppas kinetics. Thus, HME coupled with µIM proved to be a promising approach towards a continuous automated manufacturing process for the production of oral solid dispersions of benzimidazole anthelmintics to grazing cattle. Full article

High wear rates and frictional coefficients have always been the primary reasons for limiting the service life of critical elements such as pumps, couplings, bushings, bearings and gears. The premature and erratic failures are costing the industries extensive amounts of money every year. Additionally, under severe service conditions, the wear resistance requirements are higher, which greatly hinders the application of neat thermoplastics in different sectors. Hence, it is vital to enhance the tribological characteristics of thermoplastics. The mechanical and tribological properties of Polyamide 6, Thermoplastic Polyurethane, and glass fibre reinforced (GFR) Polyadmide 6 Composites of variable fibre volume fractions were investigated. Pin specimens of Polyamide 6 reinforced with (25%, 33%, and 50%) by volume of fibres were fabricated by an injection moulding process. The specimens were tested for tensile, compression, hardness, and wear under dry abrasive conditions using a pin-on-disc setup. Furthermore, the samples were scanned using micro-computed tomography (micro-CT), and the worn-out samples were analysed using field emission scanning electron microscopy. The experimental results showed that the fibre volume fraction was inversely proportional to the wear resistance of the prepared composite materials. This research will enable the industry partners to supply cutting-edge technologies to the global oil and gas industry that not only minimizes the well running cost but also improves the well resilience. Full article

Stereolithography (SL) additive manufacturing process provides increased dimensional precision, smooth surface finish and printing resolution range in the order of magnitude of 100 μm, allowing to obtain intricate 3D geometries. The incorporation of ceramic-based inclusions within liquid resins enhances the thermal and mechanical properties of the final 3D printed component while improving the surface finishing of the final parts; in this way, it expands the range of process applications and reduces the post-processing steps. The proposed approach investigates the bulk modification of commercial SLA resins mixed with ceramic powders of Al₂O₃ (grain size 1–10 μm) and SiO₂ (grain size 55–75 nm) aiming to improve 3D printed parts performance in terms of mechanical properties, dimensional stability and surface finishing compared with pure, unmodified resins. The produced materials were used for the development of inserts for injection moulding and were examined for their performance during the injection moulding process. The addition of particles in the nano- and micro-range is being employed to improve parts performance for rapid tooling applications whilst maintaining 3D printing accuracy, thermal and mechanical properties as well as achieving a smooth surface finishing compared with unmodified resins. Full article

Thermomechanical pulp (TMP) fibres can serve as renewable, cost-efficient and lightweight reinforcement for thermoplastic polymers such as poly(lactic acid) (PLA). The reinforcing ability of TMP fibres can be reduced due to various factors, e.g., insufficient dispersion of the fibres in the matrix material, fibre shortening under processing and poor surface interaction between fibres and matrix. A two-level factorial design was created and PLA together with TMP fibres and an industrial and recyclable side stream were processed in a twin-screw microcompounder accordingly. From the obtained biocomposites, dogbone specimens were injection-moulded. These specimens were tensile tested, and the compounding parameters statistically evaluated. Additionally, the analysis included the melt flow index (MFI), a dynamic mechanical analysis (DMA), scanning electron microscopy (SEM) and three-dimensional X-ray micro tomography (X-$\mathsf{\mu }$CT). The assessment provided insight into the microstructure that could affect the mechanical performance of the biocomposites. The temperature turned out to be the major influence factor on tensile strength and elongation, while no significant difference was quantified for the tensile modulus. A temperature of 180 °C, screw speed of 50 rpm and compounding time of 1 min turned out to be the optimal settings. Full article

Polymeric micro devices are gaining huge market potential in broad areas of medical devices, diagnostic devices, drug delivery, and optical applications. Current research is focusing on developing functional polymeric micro devices on a mass-production scale. Microinjection moulding is a promising technique suitable for fabricating polymeric micro devices. This review aims to summarise the primary achievements that have been achieved in various aspects of microinjection moulding of polymer micro devices, consisting of micro parts and micro surface structures. The relationships of the machine, process, rheology, tooling, micro/nanoscale replication, morphology, properties, and typical applications are reviewed in detail. Finally, a conclusion and challenges are highlighted. Full article

This paper deals with predicting the effective thermal conductivity (ETC) of injection-moulded short fibre reinforced polymers (SFRPs) using two different homogenisation schemes: a scheme based on the dielectric theory for pseudo-oriented inclusions and a two-step homogenisation model based on the mean-field homogenisation approach. In both cases, the fibre orientation tensor (FOT) obtained from Autodesk Moldflow^® simulation was used. The Moldflow FOT predictions were validated via structure tensor analysis of micro-computed X-ray tomography (micro-CT) scans of the part. In the dielectric-wise approach, the orientation of fibres was originally defined by a scalar parameter, which is related to the diagonal components of the FOT. In the two-step homogenisation approach, an interpolative model based on the Mori–Tanaka theory is used in the first step for calculating the ETC for the ideal case of unidirectional fibre alignment, followed by a second step in which orientation averaging based on the FOT inside each element is applied. The ETC was calculated using both schemes for the specific case of uniform fibre orientation distribution and at three different locations with non-identical FOTs of an injection-moulded SFRP part. The results are compared with each other and evaluated against the direct numerical simulation for the uniform fibre orientation and experimental measurements for the injection-moulded SFRP. This shows that while the two-step homogenisation can predict the ETC in the full range of orientations between the perfectly aligned and uniformly distributed fibres, the dielectric-wise approach is only capable of modelling the ETC when distributions are close to the two extreme ends of the orientation spectrum. Full article

Polymer surfaces are increasingly being functionalized with micro- and nano- surface features using mass replication methods such as injection moulding. An example of these are microneedle arrays, which contain needle-like microscopic structures, which facilitate drug or vaccine delivery in a minimally invasive way. In this study, the replication fidelity of two types of solid polycarbonate microneedles was investigated using injection compression moulding and conventional injection moulding. Using a full factorial design of experiments for the injection moulding process, it was found that the volumetric injection rate had the largest positive effect on the replication fidelity. The mould temperature and holding pressure were also found to have a positive effect, while the effect of the melt temperature was found to be insignificant for the considered temperature range. For the injection compression moulding process, it was found that a larger compression stroke resulted in a better replication fidelity. A comparison between the replication fidelity for the injection moulding and injection compression moulding indicated that the injection compression moulding process resulted in a higher and more uniform replication fidelity. Using finite element flow simulations, a higher and more evenly distributed cavity pressure was observed compared to the conventional injection moulding process. Full article

The microrheological phenomenon of kaolin-filled polypropylene (kaolin/PP) composites was investigated for the first time. The microviscosity of kaolin/PP composites was studied by changing the melt temperature and shear rate. Then, injection moulding experiments of rectangular microgrooves with different aspect ratios using kaolin/PP composites and mechanical property tests of the samples were carried out. The results showed that with increasing kaolin content, the microviscosity of the kaolin/PP composites gradually increases. The shear rate had the greatest influence on the microviscosity, and the kaolin content had the least influence. When the aspect ratio of rectangular microgrooves is small, with an increasing kaolin content, the microgroove filling rate increases, and the microstructured sample geometric shape replication effect is good; however, when the aspect ratio reaches 10:1, the microgroove filling rate decreases with an increasing kaolin content. The microstructured sample geometric shape replication effect is also poor, and size effects appear. Different factors control the microrheological morphology of composites with different aspect ratios, including the shear deformation and viscous flow of composites. The increase in kaolin content leads to a decrease in the friction coefficient and an increase in the wear resistance of the composites. We concluded that the best composite formulation for kaolin/PP composites in microinjection is the 7KL/PP composite with 7% kaolin. When the aspect ratio is 5:1, the reproduction of the microstructured sample geometry is the best, and the comprehensive mechanical properties of the sample are the best. Full article