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Griffiths CA, Rees A, Morgan A, Korkees F. Optimisation of 3D Printing for Microcellular Polymers. Polymers (Basel) 2023; 15:3910. [PMID: 37835959 PMCID: PMC10575440 DOI: 10.3390/polym15193910] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/25/2023] [Revised: 09/14/2023] [Accepted: 09/26/2023] [Indexed: 10/15/2023] Open
Abstract
Polymers are extensively used in various industries due to their versatility, durability and cost-effectiveness. To ensure functionality and longevity, polymer parts must have sufficient strength to endure external forces without deformation or breakage. Traditional approaches to increasing part strength involve adding more material; however, balancing strength to weight relationships is challenging. This paper explorers the viability of manufacturing lightweight components using a microcellular foaming polymer. Microcellular foaming has emerged as a helpful tool to achieve an optimal strength-to-weight ratio; offering advantages such as lightweight, improved mechanical properties, reduced material usage, better insulation and improved cost-effectiveness. It can also contribute to improved fuel efficiency and reduced carbon emissions, making them environmentally favourable. The combination of additive manufacturing (AM) and microcellular foaming has opened new possibilities for design innovation. This text highlights the challenges and efforts in incorporating foaming techniques into 3D printing processes, specifically fused filament fabrication (FFF). This study reveals that microcellular polymers are a viable option when balancing part strength and weight. The experiments completed during the formulation of this paper demonstrated that lightweight LW-PLA parts were significantly lighter than standard PLA parts and that a design of experiments approach can be used to optimise strength properties and provide insights into optimising manufacturability. Microcellular polymers present an opportunity for lighter and stronger 3D printed parts, offering potential energy and material savings for sustainable manufacturing practices.
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Gao X, Chen Y, Xu Z, Zhao L, Hu D. Supercritical CO 2 Foaming of Thermoplastic Polyurethane Composite: Simultaneous Simulation of Cell Nucleation and Growth Coupling in Situ Visualization. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.2c02431] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Xiulu Gao
- State Key Laboratory of Chemical Engineering, Shanghai Key Laboratory of Multiphase Materials Chemical Engineering, School of Chemical Engineering, East China University of Science and Technology, Shanghai 200237, China
| | - Yichong Chen
- State Key Laboratory of Chemical Engineering, Shanghai Key Laboratory of Multiphase Materials Chemical Engineering, School of Chemical Engineering, East China University of Science and Technology, Shanghai 200237, China
| | - Zhimei Xu
- State Key Laboratory of Chemical Engineering, Shanghai Key Laboratory of Multiphase Materials Chemical Engineering, School of Chemical Engineering, East China University of Science and Technology, Shanghai 200237, China
| | - Ling Zhao
- State Key Laboratory of Chemical Engineering, Shanghai Key Laboratory of Multiphase Materials Chemical Engineering, School of Chemical Engineering, East China University of Science and Technology, Shanghai 200237, China
| | - Dongdong Hu
- State Key Laboratory of Chemical Engineering, Shanghai Key Laboratory of Multiphase Materials Chemical Engineering, School of Chemical Engineering, East China University of Science and Technology, Shanghai 200237, China
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Sansone ND, Razzaz Z, Salari M, Tuccitto AV, Aguiar R, Leroux M, Lee PC. Tailoring Multifunctional and Lightweight Hierarchical Hybrid Graphene Nanoplatelet and Glass Fiber Composites. ACS APPLIED MATERIALS & INTERFACES 2022; 14:40232-40246. [PMID: 36000496 DOI: 10.1021/acsami.2c11231] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/15/2023]
Abstract
In this work, hybrid polypropylene (PP)-based composites reinforced with graphene nanoplatelets (GnPs) and glass fiber (GF) were fabricated by injection molding to elucidate how the hybrid approach can produce synergistic effects capable of achieving properties and functionalities not possible in biphasic composites. Synergism between the reinforcements translated to improved mechanical performance, which was attributed to the chemically and/or electrostatically assembled hierarchical structure that facilitates load transfer at the interface while simultaneously tailoring the crystalline microstructure of the matrix by inducing transcrystallization and β-crystal formation. It was demonstrated that there exists an optimal concentration of 0.5 wt % GnP, producing the greatest mechanical properties and synergistic effect, corresponding to the highest degree of crystallinity (∼6% greater than Neat PP) and peak formation of β-crystals within the PP matrix. The greatest synergistic effect was found to be ∼52 and ∼39% for the specific tensile strength and flexural strength, respectively. The same optimal concentration of GnPs was found to produce the highest synergistic effect for thermal conductivity of ∼68% due to the volume exclusion effect induced by the GFs combined with the higher crystallinity of the microstructure, promoting the formation of thermally conductive pathways. Ultimately, the mechanisms contributing to the synergistic effect presented in this work can be used to maximize the performance of hybrid composite systems, giving them the potential to be tailored for a variety of high-performance industrial applications to meet the rising demands for ultra-strong, thermally conductive, and lightweight materials.
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Affiliation(s)
- Nello D Sansone
- Multifunctional Composites Manufacturing Laboratory (MCML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
| | - Zahir Razzaz
- Multifunctional Composites Manufacturing Laboratory (MCML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
- Axiom Group Inc., 115 Mary Street, Aurora L4G 1G3, Canada
| | - Meysam Salari
- Multifunctional Composites Manufacturing Laboratory (MCML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
- Microcellular Plastics Manufacturing Laboratory (MPML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
| | - Anthony V Tuccitto
- Multifunctional Composites Manufacturing Laboratory (MCML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
- Microcellular Plastics Manufacturing Laboratory (MPML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
| | - Rafaela Aguiar
- Multifunctional Composites Manufacturing Laboratory (MCML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
| | - Matthew Leroux
- Axiom Group Inc., 115 Mary Street, Aurora L4G 1G3, Canada
| | - Patrick C Lee
- Multifunctional Composites Manufacturing Laboratory (MCML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
- Microcellular Plastics Manufacturing Laboratory (MPML), Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto M5S 3G8, Canada
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Visual observation and Numerical Studies of bubble formation of polypropylene chemical foaming system in the different injection foaming environment. JOURNAL OF POLYMER RESEARCH 2022. [DOI: 10.1007/s10965-022-03183-3] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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Shaayegan V, Wang C, Ataei M, Costa F, Han S, Bussmann M, Park CB. Supercritical CO2 utilization for development of graded cellular structures in semicrystalline polymers. J CO2 UTIL 2021. [DOI: 10.1016/j.jcou.2021.101615] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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In-Situ Visualization of the Cell Formation Process of Foamed Polypropylene under Different Foaming Environments. Polymers (Basel) 2021; 13:polym13091468. [PMID: 34062824 PMCID: PMC8125430 DOI: 10.3390/polym13091468] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/01/2021] [Revised: 04/24/2021] [Accepted: 04/26/2021] [Indexed: 11/16/2022] Open
Abstract
In this paper, the dynamic foaming process of micro-foaming polypropylene (PP) in different foaming environments in real time was obtained via a visualization device. The relationship curve between cell number (n) and foaming time (t) was plotted, and then the nucleation kinetics of foam cells was analyzed. Results showed that the formation rate of cells changed obviously with the variation of melt temperature and the content of the foaming agent. The n-t curves presented a typical "S" shape, which indicated that the appearance of the cell number increased slowly in the initial foaming period, then increased rapidly in a short time, and finally maintained a certain value. When a certain pressure was applied to the PP melt, the external force had a great influence on the n-t curve. With the increasing external force, the rate of cell formation increased rapidly, and the shape of the n-t curve changed from "S" to "semi-S" without an obvious slow increase. The investigation of the n-t relationship in the PP dynamic foaming process under different foaming environments could provide effective bases for improving the foaming quality of injection molding foaming materials.
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Li S, Sun X, Wang R, Hu Y, Ma X, Wang J. Experimental investigation on the forming and evolution process of cell structure in gas counter pressure assisted chemical foaming injection molded parts. J CELL PLAST 2020. [DOI: 10.1177/0021955x20950224] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
By using a standard stretch spline as the research object, the influence of gas counter pressure (GCP) technology on melt foaming behavior in chemical foaming injection molding (CFIM) process was investigated. Related experimental line for GCP assisted CFIM foam was designed, and the effect of GCP technology on melt flow front, spline surface quality and internal cell was studied. According to the results obtained from the experiment, two critical GCP pressures and one critical GCP holding time were innovation proposed. Two critical GCP pressures are the critical GCP pressure of melt flow front cell not cracking and the critical GCP pressure of melt not foaming, respectively. The critical GCP holding time is the secondary foaming behavior time. Based on the proposed critical GCP pressures and critical GCP holding time, the influence mechanism of GCP technology on melt foaming action during CFIM process was revealed.
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Affiliation(s)
- Shuai Li
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | - Xuemei Sun
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | - Rui Wang
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | - Yanyan Hu
- Department of Pediatrics, Linyi People’s Hospital, Linyi, PR China
| | - Xiaofei Ma
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
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Highly expanded fine-cell foam of polylactide/polyhydroxyalkanoate/nano-fibrillated polytetrafluoroethylene composites blown with mold-opening injection molding. Int J Biol Macromol 2020; 155:286-292. [DOI: 10.1016/j.ijbiomac.2020.03.212] [Citation(s) in RCA: 24] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/24/2020] [Revised: 03/21/2020] [Accepted: 03/25/2020] [Indexed: 11/17/2022]
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Abstract
Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.
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Affiliation(s)
| | - Andrew Rees
- College of Engineering, Swansea University, Swansea, UK
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Accurate theoretical modeling of cell growth by comparing with visualized data in high-pressure foam injection molding. Eur Polym J 2019. [DOI: 10.1016/j.eurpolymj.2019.07.023] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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Tromm M, Shaayegan V, Wang C, Heim HP, Park CB. Investigation of the mold-filling phenomenon in high-pressure foam injection molding and its effects on the cellular structure in expanded foams. POLYMER 2019. [DOI: 10.1016/j.polymer.2018.11.006] [Citation(s) in RCA: 27] [Impact Index Per Article: 5.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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Lee JW, Lee RE, Wang J, Jung PU, Park CB. Study of the foaming mechanisms associated with gas counter pressure and mold opening using the pressure profiles. Chem Eng Sci 2017. [DOI: 10.1016/j.ces.2017.04.005] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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Shaayegan V, Wang C, Costa F, Han S, Park CB. Effect of the melt compressibility and the pressure drop rate on the cell-nucleation behavior in foam injection molding with mold opening. Eur Polym J 2017. [DOI: 10.1016/j.eurpolymj.2017.05.003] [Citation(s) in RCA: 34] [Impact Index Per Article: 4.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
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