Search Results (33)

Proximal humerus fractures are frequent injuries that often require internal fixation. Conventional metallic plates, however, present significant drawbacks such as corrosion, secondary removal surgeries, and adverse reactions in patients with metal hypersensitivity. This study evaluates biocomposite plates fabricated from polylactic acid (PLA) and polyvinyl alcohol (PVA), reinforced with hydroxyapatite (HA) derived from sugar industry by-products (BCF) at 10% and 20% concentrations. These composites are compatible with both injection molding and 3D printing, enabling the design of patient-specific implants. Characterization by SEM, FTIR, XRD, and DSC confirmed that BCF incorporation enhances strength, stiffness, osteoconductivity, and biocompatibility. Mechanical testing showed that PVA/BCF exhibited greater tensile strength and stiffness, suggesting suitability for load-bearing applications, though their water solubility restricts use in humid environments and prevents filament-based 3D printing. PLA/BCF composites demonstrated better processability, favorable mechanical performance, and compatibility with both manufacturing routes. Finite element analysis highlighted the importance of plate–humerus contact in stress distribution and fixation stability. Compared with non-biodegradable thermoplastics such as PEI and PEEK, PLA/BCF and PVA/BCF offer the additional advantage of controlled biodegradation, reducing the need for secondary surgeries. Cell viability assays confirmed cytocompatibility, with optimal outcomes at 10% BCF in PVA and 20% in PLA. These results position PLA/BCF and PVA/BCF as sustainable, patient-tailored alternatives to metallic implants, combining adequate mechanical support with bone regeneration potential. Full article

The impact of adding 1%, 3%, and 5% by mass of kaolin residue (KR) was investigated regarding the mechanical, thermomechanical, and morphological properties, as well as the non-isothermal crystallization and melting kinetics of poly(ε-caprolactone) (PCL). The processing to obtain the PCL/KR composites was carried out through extrusion in a twin-screw extruder, followed by injection molding. This study investigated the events of first melting, fusion crystallization, and second melting using differential scanning calorimetry (DSC), with heating rates ranging from 5 to 25 °C/min. Additionally, models for the expanded Prout–Tompkins equation (BNA), the nth-order reaction with m-power autocatalysis by product (Cnm), and the Sestak and Berggren equation (SB) were tested. The PCL/KR composites exhibited an increase in the elastic modulus and the heat deflection temperature (HDT) compared to the pure PCL. Furthermore, high ductility was observed, as evidenced by the impact strength and elongation at break. The good distribution of KR in the PCL matrix was confirmed by scanning electron microscopy (SEM), which contributed to a more efficient crystallization process. The increase in KR content in the PCL matrix shifted the crystallization sigmoids to higher temperatures, acting as a nucleating agent, which reduced the energy barriers and increased the crystallization temperature by up to 5 °C. The melting events did not show significant changes with the addition of the KR. The results are important for the plastics processing industry, mainly due to the opportunity to add value to the waste and use it as an additive. Full article

The immiscibility of thermoplastic starch (TPS) and polybutylene succinate (PBS) complicates the thermal processing of these materials. This study provides the first comparative assessment of two compatibilizers with differing reaction mechanisms, Joncryl^® ADR 4468 and epoxidized linseed oil (ELO), for the optimization of biobased TPS/PBS blends. A total of 13 batches, varying in compatibilizer and blend composition, were processed via hot melt extrusion and injection molding to produce pellets. Blends were analyzed using tensile and impact testing, differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR), rheology, and scanning electron microscopy (SEM). The findings suggest that both compatibilizers can improve the compatibility of these blends, as evidenced by higher glass transition temperatures (T_g) compared to the reference batch (100-0-N/A). Joncryl^® ADR 4468 batches exhibit superior tensile strength and Young’s moduli, while ELO batches demonstrate greater elongation at break. The enhanced processability observed in Joncryl^® ADR 4468 is attributed to the increased polymer chain entanglement and molecular weight, whereas ELO facilitates greater chain mobility due to its plasticizing effect. These differences arise from the distinct mechanisms of action: Joncryl^® ADR 4468 promotes chain extension and crosslinking, whereas ELO mainly enhances flexibility through plasticization. Overall, this study provides a comparative assessment of these compatibilizers in TPS/PBS blends, laying the groundwork for future investigations into optimizing compatibilizer concentration and blend composition. Full article

Dielectric materials have gained traction for their energy-storage capacitive and electrically insulating properties as sensors and in smart surface technologies such as in In-Mold Electronics (IME). IME is a disruptive technology that involves environmentally protected electronics in plastic thermoformed and molded structures. The use of IME in a human–machine interface (HMI) provides a favorable experience to the users and helps reduce production costs due to a smaller list of parts and lower material costs. A few functional components that are compatible with one another are crucial to the final product’s properties in the IME structure. Of these components, the dielectric layers are an important component in the smart surface industry, providing insulation for the prevention of leakage currents in multilayered printed structures and capacitance sensing on the surface of specially designed shapes in IME. Advanced dielectric materials are non-conductive materials that impend and polarize electron movements within the material, store electrical energy, and reduce the flow of electric current with exceptional thermal stability. The selection of a suitable dielectric ink is an integral stage in the planning of the IME smart touch surface. The ink medium, solvent, and surface tension determine the printability, adhesion, print quality, and the respective reaction with the bottom and top conductive traces. The sequence in which the components are deposited and the heating processes in subsequent thermoforming and injection molding are other critical factors. In this study, various commercially available dielectric layers were each printed in two to four consecutive layers with a mesh thickness of 50–60 µm or 110–120 µm, acting as an insulator between conductive silver traces overlaid onto a polycarbonate substrate. Elemental mapping and optical analysis on the cross-section were conducted to determine the compatibility and the adhesion of the dielectric layers on the conductive traces and polycarbonate substrate. The final selection was based on the functionality, reliability, repeatability, time-stability, thickness, total processing time, appearance, and cross-sectional analysis results. The chosen candidate was then placed through the final product design, circuitry design, and plastic thermoforming process. In summary, this study will provide a general guideline to optimize the selection of dielectric inks for in-mold electronics applications. Full article

Joining materials with different physicochemical properties presents significant challenges. This study investigates the one-step anodization of aluminum in a mixed phosphoric acid and hydrogen peroxide solution, followed by the direct injection molding of polymer resin to enhance joint properties. The anodizing treatment is performed at constant electrical current with phosphoric acid solutions of various concentrations. Phosphoric acid anodizing enables the formation of 3D channeling pore structure with micropits and uniform nanopores on the aluminum surface. Hydrogen peroxide acts as an oxidizing agent and promotes the dissolution reaction, thereby increasing the size of the nanopores. Larger pores facilitated the penetration of polymer resin into the aluminum oxide layer during injection molding, resulting in bonding strengths up to 40.34 MPa. This improvement is substantial when compared to the bonding strengths achieved through conventional injection molding processes. These results highlight that the increase in nanopore size due to hydrogen peroxide addition played a critical role in enhancing the bonding strength, as it facilitated better penetration and interlocking of the polymer resin within the anodized aluminum layer. Furthermore, a three-dimensional (3D) printing process was able to join polymer resins to the anodized aluminum surface, where the larger nanopores with the addition of the hydrogen peroxide is more beneficial to the bonding strengths than the direct injection molding is. This alternative approach addresses the environmental issues associated with the use of Cr(VI)-based anodizing solutions and the lightweight composites with applicability to various industries that could be produced using this method. Full article

Selecting the optimal settings for the production of rubber goods can be a very time-consuming and resource-intensive process. A promising method for optimizing rubber processing in a short period of time is the use of simulation routines. However, process simulations have only recently enabled meaningful predictions of not only the part’s state of cure but also its mechanical characteristics. As a first approach, second-order polynomials were considered suitable for describing the properties of compression-molded parts. However, more precision is required for injection molding due to the narrower distribution of mechanical characteristics of parts produced at different vulcanization temperatures. This became evident when the approximation of mechanical data with second order models partly revealed significant failures of part behavior prediction. To tackle this issue, a combined approach for approximation is proposed in this contribution by means of logistic growth function in addition to second order polynomials. To feed the model, an experimental plan was designed for producing injection-molded parts from an SBR compound at various temperatures and to different degrees of cure. The parts obtained were then characterized mechanically, and the results were opposed to varying degrees of cure and extents of reaction to calculate the model coefficients. Once available, a simulation-based calculation of the mechanical part quality is possible. The comparison of test results from the simulation and the real process has shown a reliable prediction, as simulation results were found within the natural deviation of the real measurements. Full article

Microdroplets have been widely used in different fields due to their unique properties, such as compartmentalization, single-molecule sensitivity, chemical and biological compatibility, and high throughput. Compared to intricate and labor-intensive microfluidic techniques, the centrifuge-based method is more convenient and cost-effective for generating droplets. In this study, we developed a handy injection molding based method to readily produce monodisperse droplets by centrifugation. Briefly, we used two three-dimensional (3D) printed master molds with internal cavities to forge two coupled sub-molds by injecting polydimethylsiloxane (PDMS) and casted these two PDMS sub-molds into a nested structure that clamps the micro-channel array (MiCA) by injecting polyurethane resin. This method enables the generation of various sizes of monodispersed microdroplets by centrifugation with proper parameters within 10 min. To assess the performance of this method, homogeneous fluorescent hydrogel microspheres were generated and droplet digital polymerase chain reaction (ddPCR) was carried out. Overall, this method offers high-throughput droplet generation, reduces costs compared to other methods, and is user-friendly. Full article

The development of polymeric biocomposites containing natural fibers has grown over the years due to the properties achieved and its eco-friendly nature. Thus, biocomposites involving a polymer from a renewable source (Biopolyethylene (BioPE)) and babassu fibers (BFs), compatibilized with polyethylene grafted with maleic anhydride (MA) and acrylic acid (AA) (PE-g-MA and PE-g-AA, respectively) were obtained using melt mixing and injection molded into tensile, impact, and HDT specimens. Babassu fiber was characterized with Fourier transform infrared spectroscopy (FTIR), thermogravimetry (TGA), and scanning electron microscopy (SEM). The biocomposites were characterized using torque rheometry, TGA, tensile strength, impact strength, thermomechanical properties, Shore D hardness, and SEM. The data indicate that the torque during the processing of compatibilized biocomposites was higher than that of BioPE/BF biocomposites, which was taken as an indication of a possible reaction between the functional groups. Compatibilization led to a substantial improvement in the elastic modulus, tensile strength, HDT, and VST and a decrease in Shore D hardness. These results were justified with SEM micrographs, which showed babassu fibers better adhered to the surface of the biopolyethylene matrix, as well as an encapsulation of these fibers. The system investigated is environmentally sustainable, and the results are promising for the technology of polymeric composites. Full article

The copolymers of cycloolefin (COC), a type of thermoplastic material, have been widely used for the large-scale industrial fabrication of droplet microfluidic devices, which is often performed using hot-embossing or injection-molding techniques. The generation of droplets and the uniformity of droplet sizes are significantly affected by the surface wettability of COC during fabrication and the pressure stability of the employed fluid pump during operation. In order to alleviate the effects of undesirable surface wettability and pressure variation on the generation of droplets in COC-based devices, a simple surface modification procedure was applied to hydrophobically modify the surfaces of COC-based microchannels for large-scale industrial production. The surface modification procedure consisted of an oxygen plasma treatment of the polymer surface followed by a solution-phase reaction in fluorocarbon solvent. The experimental results demonstrate that following the proposed surface modification, the COC droplet microfluidic devices could stably generate microvolume water droplets with a small coefficient of variation, even if the pressure of the dispersed phase (water) fluctuated. The durability test results regarding the modified surfaces show that the hydrophobicity of the modified COC surfaces could be sustained for up to four months, deteriorating with time thereafter. Our study can provide a potential solution useful in and guidance for the large-scale industrial production of droplet microfluidic devices for various applications, including polymerase chain reaction and single-cell analysis. Full article

This review paper presents an overview of the state of the art on process-induced degradation of poly(lactic acid) (PLA) and the relative importance of different processing variables. The sensitivity of PLA to degradation, especially during melt processing, is considered a significant challenge as it may result in deterioration of its properties. The focus of this review is on degradation during melt processing techniques such as injection molding and extrusion, and therefore it does not deal with biodegradation. Firstly, the general processing and fundamental variables that determine the degradation are discussed. Secondly, the material properties (for example rheological, thermal, and mechanical) are presented that can be used to monitor and quantify the degradation. Thirdly, the effects of different processing variables on the extent of degradation are reviewed. Fourthly, additives are discussed for melt stabilization of PLA. Although current literature reports the degradation reactions and clearly indicates the effect of degradation on PLA’s properties, there are still knowledge gaps in how to select and predict the processing conditions that minimize process-induced degradation to save raw materials and time during production. Full article

Due to the increasing demand for electro mobility and specifically for electrified vehicles, the demand for electric drive technology is expanding significantly with changing requirements in terms of the process and the application. The electrical insulation system of the stator is an essential part of the fabrication process with a high impact on the application properties. Due to limitations—for example, in terms of suitable materials for the stator insulation—a new technology of integrated fabrication by injection molding of thermosets has been founded. In this study, two epoxy (EP) types with different fillers were investigated to prove their suitability in terms of the material properties in the fabrication process and the application. A general realization of the integrated fabrication of insulation systems in electrical engineering by injection molding was proved. Further, the differences regarding the suitability of the two materials are portrayed. It was demonstrated that mainly the filler material influences the fabrication process and the properties in the application, leading to differing suitability in terms of the EP 3162 EMG within the fabrication process and in terms of XW 6640-1 within the application properties of the thermal conductivity and the thermal linear expansion. It was further shown that the filler within the material system is required to increase the thermal conductivity needed for the application. The inclusion of the filler influences the reaction kinetics and the viscosity behavior. A fabrication of the material with fillers is however still possible. Full article

There is a wide application field for anti-adhesive and hydrophobic coatings, stretching from self-cleaning surfaces over anti-graffiti and release coatings to demolding aids in the production of polymers. The typical materials for the latter are hard coatings, including TiN, CrN, diamond-like carbon, etc. Alternatively, organosilane coatings based on perfluorinated compounds or molecules with long alkyl side chains can be employed. Although these functional layers are generally required to be invisible, there is a demand for a straightforward approach, which enables the temporary control of successful and homogeneous application as well as abrasion and wear of the coatings during use. For this purpose, a visibility-on-demand property was introduced to an already established anti-adhesive organosilane coating by incorporation of 1,8-naphthalimide-N-propyltriethoxysilane (NIPTES) as a fluorescent marker molecule. While the naphthalimide unit provides blue fluorescence under UV irradiation, the ethoxy groups of NIPTES enable the covalent coupling to the coating as a result of the hydrolysis and condensation reactions. As a consequence, the fluorescent marker molecule NIPTES can simply be added to the coating solution as an additional organosilane component, without the need for changes in the approved deposition procedure. The generated fluorescent anti-adhesive coatings were characterized by contact angle measurements, atomic force microscopy (AFM), as well as by different spectroscopic techniques, including FTIR, UV-Vis, fluorescence and X-ray photoelectron spectroscopy (XPS). In addition, the on-demand control function provided by the introduced fluorescence properties was evaluated along an injection molding process. Full article

The applications of bonded magnets in the field of injection-molded samples can be expanded by thermoset-based polymer-bonded magnets, as thermosets provide the opportunity to comply with the demands of, for example, the chemical industry or pump systems in drive applications through to their improved chemical and thermal resistance, viscosity and creep behaviour, especially compared to thermoplastic-based magnets. This paper investigates the influence of the matrix material (epoxy resin, phenolic resin), the filler type (strontium-ferrite-oxide, neodymium-iron-boron) and the filler grade on the reaction kinetics and the viscosity. Based on the determination of the impact, the theory of the network structure is founded. The network and the cross-linked structure are essential to know, as they significantly define not only the material but also the sample behaviour. The correlation between the material system and the mechanical as well as the magnetic properties is portrayed based on the general understanding of the behaviour in terms of the reaction kinetics and the viscosity as well as the theory of the network structure. With that, a basic understanding of the correlation within the material system (matrix, filler, filler grade) and between the reaction kinetics, the network and the cross-linked structure was determined, which gives the opportunity to change the mechanical and the magnetic properties based on the analyzed impact factors and to expand the applications of bonded magnets in the field of thermoset-based ones. Full article

Microfluidic platform technology has presented a new strategy to detect and analyze analytes and biological entities thanks to its reduced dimensions, which results in lower reagent consumption, fast reaction, multiplex, simplified procedure, and high portability. In addition, various forces, such as hydrodynamic force, electrokinetic force, and acoustic force, become available to manipulate particles to be focused and aligned, sorted, trapped, patterned, etc. To fabricate microfluidic chips, silicon was the first to be used as a substrate material because its processing is highly correlated to semiconductor fabrication techniques. Nevertheless, other materials, such as glass, polymers, ceramics, and metals, were also adopted during the emergence of microfluidics. Among numerous applications of microfluidics, where repeated short-time monitoring and one-time usage at an affordable price is required, polymer microfluidics has stood out to fulfill demand by making good use of its variety in material properties and processing techniques. In this paper, the primary fabrication techniques for polymer microfluidics were reviewed and classified into two categories, e.g., mold-based and non-mold-based approaches. For the mold-based approaches, micro-embossing, micro-injection molding, and casting were discussed. As for the non-mold-based approaches, CNC micromachining, laser micromachining, and 3D printing were discussed. This review provides researchers and the general audience with an overview of the fabrication techniques of polymer microfluidic devices, which could serve as a reference when one embarks on studies in this field and deals with polymer microfluidics. Full article

In recent, large case series of fungal endophthalmitis (FE) that were published by Asian authors, the most frequent etiologic agents for all types of FE are molds (usually Aspergillus species, while Fusarium is the prevalent etiology in keratitis-related FE). Candida was the organism found in most cases of endogenous FE. However, we must keep in mind that prevalence of fungal species varies with the geographical area. Lately, polymerase chain reaction (PCR) was increasingly used for the diagnosis of FE, allowing for very high diagnostic sensitivity, while the costs become more affordable with time. The most important shortcoming of PCR—the limited number of pathogens that can be simultaneously searched for—may be overcome by newer techniques, such as next-generation sequencing. There are even hopes of searching for genetic sequences that codify resistance to antifungals. We must not forget the potential of simpler tests (such as galactomannan and β-d-glucan) in orienting towards a diagnosis of FE. There are few reports about the use of newer antifungals in FE. Echinocandins have low penetration in the vitreous cavity, and may be of use in cases of fungal chorioretinitis (without vitritis), or injected intravitreally as an off-label, salvage therapy. Full article