Search Results (439)

Eco-friendly biocomposites were prepared from poly(lactic acid) (PLA) plasticized with polyethylene glycol (PEG) and reinforced with Moroccan sugarcane bagasse fibers at 5, 10 and 15 wt%. The aim was to enhance PLA ductility through PEG incorporation while valorizing locally available lignocellulosic residues. Two processing methods, injection molding and melt extrusion additive manufacturing (MEX, 3D printing), were employed to investigate the influence of manufacturing method on the morphological, thermal, rheological and mechanical properties of the composites. Thermal analysis confirmed that PLA maintained its stability within the processing temperature range, supporting its suitability for MEX. Morphological observations revealed improved fiber dispersion and reduced porosity in injection-molded samples, whereas MEX-printed parts exhibited visible interlayer voids. These microstructural differences explained the superior tensile strength and modulus of injection-molded specimens compared to MEX ones. Full article

The accuracy of gears is a determining factor for their functionality, reliability, and durability in various mechanical systems. Two widely used technologies for producing plastic gears are injection molding and 3D printing, each having its own advantages and limitations. Injection molding is a traditional method for mass production that offers high productivity but is sensitive to parameters such as temperature, pressure, and cooling, which can lead to shrinkage and dimensional instability. On the other hand, 3D printing is gaining popularity due to its flexibility, rapid prototyping capabilities, and the possibility of producing small series without the need for expensive tooling. In the present study, the accuracy of plastic gears with module 2 and module 3, manufactured using both technologies, was investigated and compared. Measurements were performed on three main parameters: span measurement, chordal tooth thickness, and measurement over pins. The obtained data were statistically analyzed and classified according to the DIN 3962/3963 and ISO 628 accuracy standards. 3D-printed gears demonstrated lower standard deviation (0.0079–0.0083 mm) and improved repeatability compared with injection-molded gears (0.0131–0.0189 mm), achieving DIN 10–14 accuracy classes. Unlike previous studies that compare different materials or technologies separately, this work directly compares both simultaneously under controlled conditions, revealing that material selection (CF-reinforced vs. unfilled POM) may influence dimensional outcomes as strongly as the manufacturing method. These findings provide practical guidance for selecting production routes for low-to-medium precision polymer gears under the tested conditions. Full article

Increasing regulatory demands for high-quality plastic recycling create a strong need for novel tracer systems that enable reliable polymer identification and sorting. This feasibility study evaluates germanium nanocrystals (GeNCs) as Raman-detectable tracer materials in polypropylene (PP). The synthesis of GeNC/PP composite materials possessing various GeNC contents via a solvent-based intercalation process followed by compounding and injection molding is reported. Hydride-terminated GeNCs were synthesized and subsequently functionalized with dodecyl ligands to ensure chemical stability, compatibility with the polymer matrix, and processability under conventional melt-processing conditions. The dodecyl-functionalized GeNCs were successfully stabilized and homogeneously integrated into the PP matrix. Raman spectroscopy demonstrates the clear detection of GeNCs within the composites through a characteristic Ge–Ge optical phonon mode at 296 cm⁻¹, which is well separated from the intrinsic Raman bands of polypropylene. The Raman signal intensity increases systematically with increasing GeNC concentration. Raman mapping reveals an overall homogeneous distribution of the nanocrystals within the polymer, while a slight tendency toward agglomeration is observed at higher loadings. These results demonstrate that GeNCs are well suited as optically detectable tracers for polypropylene and can be reliably identified using Raman spectroscopy, highlighting their potential for tracer-based sorting concepts in advanced recycling and digital material passport applications. Full article

Plastic injection molding in cleanrooms involves high thermal loads and strict particle limits. The hot surfaces of the injection molding machine and peripherals increase the cooling demand of the heating, ventilation, and air conditioning system to an undefined amount. Moreover, the generation of buoyancy-driven plumes has the potential to disturb the cleanroom airflow around the injection mold, thereby risking cross contamination of the manufactured components. The present study quantifies the global heat load of injection molding machines in an ISO Class 7 cleanroom with a laminar flow microenvironment around the mold. Therefore, a measurement-based method to determine the heat load of a complete injection molding production cell is applied to a hydraulic and an electric machine. This method revealed that the heat load of the isolated machines is process-independent, whereas the total heat load of the complete production cell scales linearly with mold temperature. Moreover, the emitted heat to the cleanroom is considerable lower than the injection molding machine’s installed power. Secondly, the airflow regime and particle transport in the mold area are analyzed. This is achieved by means of schlieren visualization and aerosol measurements. The introduction of a modified Archimedes number, incorporating mold size and convective heat flux, has led to the observation of a correlation between flow regimes and the resulting particle load. This enables the selection of case-dependent FFU velocities that deviate from the conventional recommendation of an air speed of 0.45 m/s ± 20%. Despite the presence of a filter-fan unit, the particle load near the injection mold cavity increases for flow conditions that exceed a critical Archimedes number. Full article

Bone tissue engineering requires biomimetic materials; however, pure polylactic acid (PLA) exhibits limited osteoinductivity and produces acidic byproducts upon degradation. To address these limitations, this study fabricated PLA scaffolds using fused-deposition modeling (FDM) with four distinct lattice structures (rectangular, triangular, gyroid, and 3D honeycomb) and incorporated hydroxyapatite (HA) at 0, 10, 20, and 30 wt% via injection molding. Mechanical properties were evaluated via compression, three-point bending, and tensile testing. The results revealed that increasing HA content significantly reduced structural strength and increased brittleness across all test modes. Specifically, specimens with 30 wt% HA exhibited a 70.8% reduction in bending strength relative to pure PLA (from 58.60 MPa to 17.07 MPa), while tensile strength decreased by 46.1% at just 10 wt% HA (from 37.54 MPa to 20.23 MPa). Although the triangular lattice achieved the highest absolute compressive load, the rectangular lattice provided a superior load-to-weight ratio and greater plastic deformation capacity before fracture. Consequently, these findings indicate that the rectangular pattern at 70% infill density combined with HA addition limited to ≤10 wt% represents the most mechanically balanced design for bone defect repair applications. Based on the mechanical characterization performed in this study, and drawing on published evidence regarding the biological properties of PLA/HA composites, these scaffolds represent a mechanically promising candidate for further evaluation in bone tissue regeneration. Biological validation through in vitro and in vivo studies is required before clinical relevance can be established. Full article

Concerns about the environmental and health impacts of plasticized poly (vinyl chloride) (PVC), from plasticizer loss to microplastic formation, have created a clear demand to find alternative packaging materials for medical and pharmaceutical use. As a possible polyolefin-based alternative, we blended polypropylene–ethylene copolymers with different ethylene content-controlled phase structures with styrene–ethylene/butylene–styrene block copolymer (SEBS), as modifier. SEBS is elastomeric and performs mechanically like a cross-linked rubber due to its unique microphase-separated morphology of hard spherical polystyrene (PS) domains dispersed in the soft elastomeric ethylene-butylene copolymer (EB) phase. Tests with injection-molded samples and cast films demonstrated promising combinations of flexibility, durability, and transparency—qualities essential for soft medical packaging like infusion pouches and blow–fill–seal bottles. For the desired level of flexibility (reflected by a flexural modulus of 150–250 MPa), blends with two random-heterophasic (RAHECO) copolymers achieved the lower limit with only 15–25 wt.-% SEBS, compared to the 37 wt.-% needed for a single-phase random copolymer (RACO). These blends also exhibited greater toughness and excellent transparency. In contrast, a standard impact copolymer (HECO), with its more crystalline matrix, required a higher modifier content of 45 wt.-% SEBS. Film morphology analysis indicated a gradual shift in disperse phase structure and orientation, leading to phase inversion at the highest SEBS content without negatively affecting transparency. Full article

Poly(lactic acid) (PLA)-based biocomposites incorporating collagen (COLL) and hydroxyapatite (HA) were produced via melt micro-compounding and subsequent injection molding. 1,4-phenylene diisocyanate (PDI) was employed as a compatibilizer, while poly(ethylene glycol) (PEG) was used as a plasticizer. The morphological, thermal, rheological, and mechanical properties, as well as surface wettability, degradation behavior, and cytotoxicity, were comprehensively evaluated. SEM and DSC analyses revealed the phase distribution and thermal transitions, while rheological measurements showed that PEG reduced melt viscosity by increasing chain mobility. Mechanical performance was evaluated using tensile, impact, and DMA tests on standard specimens, indicating that HA primarily enhanced stiffness (elastic modulus), whereas PEG improved toughness, resulting in higher impact strength. Biodegradable bone screw prototypes were produced with the same formulations and subjected to torsion, enzymatic degradation, and MTT cytotoxicity tests. Degradation results indicated that biocomposites containing PEG, collagen, and HA exhibited accelerated mass loss. Overall, the 70/20/10 PLA/COLL/HA/PEG/PDI formulation was more suitable for soft (trabecular) bone tissue, while the 70/10/20 PLA/COLL/HA/PDI formulation showed advantages for hard (cortical) bone tissue applications. Full article

This study presents an integrated optimization framework that combines the Design of Experiments (DOE) approach with Machine Learning (ML) techniques to minimize defects in the injection molding of Fuel Vapor Charcoal Canisters. The research focuses on five critical process parameters—melt temperature, mold temperature, filling time, pressure holding time, and pure cooling time—whose combined influence on major molding defects (warpage, shrinkage, shear stress, residual stress, and short shots) was systematically investigated. A Taguchi L25 orthogonal array was employed to structure the experiments and identify the optimal parameter levels through signal-to-noise (S/N) ratio analysis using the “smaller-the-better” quality criterion. The Taguchi results revealed that pressure holding time was the most influential factor, followed by mold temperature and melt temperature. Simulation results from SolidWorks Plastics confirmed the reduction in major defects under the optimized settings. To further validate and generalize the DOE findings, a Random Forest regression model was trained on the same dataset to capture nonlinear interactions between parameters. The model achieved an average RMSE of 2.451 ± 0.591 in five-fold cross-validation, demonstrating strong predictive accuracy. Feature importance analysis indicated that pressure holding time accounted for approximately 77.5% of the variance in the defect index, reaffirming its dominant role. A 3D response surface of the global parameter space (mold temperature vs. pressure holding time) revealed a distinct minimum defect region, consistent with the DOE-optimized settings. The Taguchi analysis identified the optimal parameter settings as Melt Temperature at Level 2, Mould Temperature at Level 3, Filling Time at Level 4, Pressure Holding Time at Level 5, and Pure Cooling Time at Level 4, which collectively produced the highest S/N ratios and the lowest overall defect index. The overall discrepancy between DOE and ML predictions was only 12.5%, confirming methodological consistency. The integration of DOE and ML not only enhances parameter interpretability and defect prediction accuracy but also provides a scalable, data-driven approach for intelligent process control and quality assurance in automotive injection molding. Full article

The study focused on the development and optimization of plastic deformation of pure M1E copper using an unconventional hydrostatic extrusion (HE) process aimed at improving the performance of electrodes used in electrical discharge machining (EDM). The process was designed to refine the microstructure while maintaining the high electrical conductivity required for EDM applications. Optimization of a three-stage HE process (cumulative strain ε = 2.51) resulted in the formation of an ultrafine-grained structure (d₂ ≈ 370 nm), leading to a significant increase in mechanical strength (UTS ≈ 400 MPa) while preserving very high electrical conductivity (~99% IACS). This combination of properties is particularly important for EDM electrodes, as it allows improved wear resistance without compromising electrical performance. Due to the application-oriented nature of the study, the HE-processed copper was tested under industrial EDM conditions. Wear tests were conducted using seven electrodes of different geometries required for the production of a sample injection mold. The results demonstrated a substantial reduction in electroerosion wear of HE-processed electrodes (30–90%) compared with undeformed copper, together with up to 25% improvement in surface quality. These findings indicate that hydrostatic extrusion is an effective method for producing high performance EDM electrode materials with improved durability and machining quality. Full article

The transition to a circular economy requires assessment tools that capture not only the environmental and economic performance of products but also their circular design, functionality, and durability. While Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) are widely used, they alone do not capture modularity, reparability, reuse potential, or product lifespan. This study introduces a novel, integrated framework combining LCA, LCC, and product-level circularity indicators to provide a holistic evaluation of sustainability and circularity. In this study, two types of injection molds for plastic part production are compared: a conventionally manufactured mold and an additively manufactured metal mold produced by Laser Powder Bed Fusion (L-PBF) technology. The comparison integrates Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and a set of micro-circularity indicators, including the Material Circularity Indicator (MCI), Recycling Desirability Index (RDI), circular design guidelines (CDG), Disassembly Effort Index (DEI), longevity indicator (LI), and Circular Economy Indicator Prototype (CEIP). Results show that the AM mold exhibits lower environmental impacts across almost all categories, while its slightly higher initial cost is largely offset by reduced indirect costs over the product lifecycle. Micro-circularity indicators reveal that the AM mold achieves higher material circularity and better circular design performance (MCI, CDG, CEIP) but shows only minor improvements in disassembly and recyclability (DEI, RDI) and lower longevity (LI) compared to the conventional mold, highlighting potential limitations for remanufacturing and end-of-life recovery. The novelty of this study lies in the integrated application of LCA, LCC, and multiple micro-circularity indicators, providing an operational framework for evaluating circular design, reparability, and durability in additive manufacturing and enabling informed, holistic decision-making for truly circular products. Full article

Injection molding is widely used for plastic parts, but its performance is limited by the cooling stage, which dominates cycle time and affects dimensional stability and energy consumption. Conformal cooling channels, which can be manufactured using additive technologies, improve thermal efficiency but introduce a high-dimensional design problem. This work proposes an integrated methodology for optimizing injection molds with conformal cooling channels that combines parametric CAD (Computer-Aided Drawing), simulation, non-linear principal component analysis, artificial neural network, and multi-objective evolutionary optimization. The workflow is applied to a case study with five cooling layouts. An initial set of 36 metrics related to temperature gradients, warpage, shrinkage, and energy is reduced to a small number of latent objectives, simplifying the search space while preserving the main physical trends. Artificial neural networks surrogates accurately reproduce numerical results, enabling exploration of the design space at a fraction of the computational cost. The optimization yields diverse Pareto-optimal solutions that balance cycle time, dimensional stability, and energy consumption, assisting the design of more sustainable injection molds. Sensitivity analysis identifies mold temperature and channel position/diameter as key design levers. The proposed methodology reduces dependence on expensive simulations and is readily transferable to industrial mold design. Full article

Fused Filament Fabrication (FFF) is a low-cost additive manufacturing process that produces metallic parts from printing with a metal-polymer filament, followed by a debinding–sintering process. It presents an opportunity for the tooling sector to improve performance by geometrical optimization while keeping costs low. This study investigates the possibility of producing a molding core for plastic injection by FFF technology. This research aimed to characterize 17-4 PH stainless steel and H13 hot work tool steels produced through this process. Their heat treatment behavior was investigated using dilatometry, which led to the obtention of a Continuous Cooling Transformation (CCT) diagram. Results show that for as-sintered materials, martensitic steel with some residual austenite is present in 17-4 PH, and a pearlitic microstructure is observed in H13. Porosity (around 4%) falls within the reported range in the literature and can be removed by hot isostatic pressing. CCT diagrams do not show significant differences with conventional materials. The low hardness of as-sintered H13 (around 175 HV1) is improved (>500 HV1) by suitable heat treatment. Finally, both materials meet the requirements for this specific industrial application, and demonstrators were produced. Full article

Polyethylene terephthalate (PET) has become the predominant material for single-use packaging owing to its cost and performance advantages. However, massive post-consumer waste leads to environmental concerns, and recycled PET from thermomechanical processing followed by chain extension often suffers from low toughness and poor processability, restricting its use to low-value applications. In this study, halloysite nanotubes (HNTs) and ethylene–methyl acrylate–glycidyl methacrylate random terpolymer (E-MA-GMA) were melt-blended with recycled PET to examine their synergistic modification effects. The DSC results show that HNTs retain a nucleating effect on recycled PET even with the co-addition of E-MA-GMA, albeit with a substantial reduction compared with their effect when used alone. Nevertheless, rheological measurements indicate that the combined introduction of E-MA-GMA and HNTs imposes a significantly stronger restriction on the relaxation behavior of recycled PET molecular chains than the individual addition of either HNTs or E-MA-GMA. This is attributed to the interfacial reactions between E-MA-GMA and the recycled PET matrix, as well as between E-MA-GMA and HNTs, leading to the formation of branching and hybrid structures. This synergistic restraint markedly reduces the crystallization growth rate of PET. As a result, the recycled PET/E-MA-GMA/HNTs composites maintain relatively lower crystallinity compared with the recycled PET/E-MA-GMA composite after high-temperature injection molding or annealing treatment, leading to superior impact resistance. The impact strength of the recycled PET/E-MA-GMA/HNTs composites is 2.28 and 2.14 times that of the recycled PET/E-MA-GMA composite under high-mold-temperature injection molding and annealing conditions, respectively. The approach presented here facilitates the substitution of virgin plastics with recycled PET in demanding applications. Full article

The COVID-19 pandemic critically emphasized the need for rapid, flexible, and decentralized manufacturing solutions to support the urgent demand for essential medical equipment, such as oximeters. Metal wire directed energy deposition—w-DED, also known as w-LMD (wire laser metal deposition)—combines the benefits of high material utilization, increased printing speed, and reduced waste, making it an attractive alternative to traditional powder-based processes, especially under time-sensitive and resource-constrained conditions. This work presents a case study focusing on the design and fabrication of injection molds for oximeter casings using metal-wire-based DED. Martensitic stainless steel AISI-420 wire was employed as feedstock and processed via laser wire additive manufacturing to produce a robust, near-net-shape mold suitable for plastic injection molding. The material was selected due to good corrosion and wear resistance. However, poor ductility and toughness, together with AM-induced anisotropy, were the main challenges to address. Therefore, a multi-step methodology was defined to study the effect of different process parameters, which was validated through printing trials, and the optimum process parameter set was identified. The process enabled the rapid construction of intricate mold geometries, minimizing lead times and allowing for quick design iterations. Microstructural and physical properties such as microhardness of the as-built molds were thoroughly characterized. This case study not only illustrates the technical feasibility of producing functional injection molds via metal w-DED but also outlines its role as a resilient manufacturing pathway, capable of meeting emergent healthcare needs and supporting broader industrial applications in a post-pandemic context. Full article

This study investigates the processability and performance limits of high-density polyethylene (HDPE) recovered from mixed polyolefin waste under realistic mechanical recycling conditions. The waste stream was processed by extrusion and injection molding, with parameters actively adapted. ATR-FTIR and DSC analysis confirmed HDPE as the matrix, contaminated with minor fractions of polypropylene (PP), PET, and polyurethane (PU). The reprocessed material exhibited a single melting peak at 132 °C and a melt flow rate (MFR) of 9.9 ± 0.6 g 10 min⁻¹, indicative of moderate degradation. Mechanical testing revealed reduced tensile strength and elongation at break compared to virgin HDPE, indicating compositional heterogeneity and poor interfacial adhesion. Field emission scanning electron microscopy (FESEM) revealed dispersed inclusions and microvoids acting as stress concentrators, consistent with reduced ductility. Crucially, progressive reduction of back pressure during processing optimization was essential for stabilizing melt flow and minimizing shear-induced degradation. This adjustment enabled consistent mold filling despite the material’s variability. The results demonstrate that mixed HDPE waste can be successfully valorized for non-structural applications such as plastic lumber or pallets, providing a sustainable pathway for recycling heterogeneous streams without costly pre-treatment or compatibilization. Full article