Effect of the main process parameters on the mechanical strength of polyphenylsulfone (PPSU) in ultrasonic micro-moulding process

Highly Permeable Ultrafiltration Membranes Based on Polyphenylene Sulfone with Cardo Fragments

For the first time, copolymers of polyphenylene sulfone (PPSU) with cardo fragments of phenolphthalein (PP) were synthesized to develop highly permeable flat-sheet ultrafiltration membranes. By introducing cardo fragments into the polymer chain, we achieved a mechanical strength 1.3 times higher than the strength of commercial PPSU. It is shown that the introduction of the cardo monomer significantly increases the solubility of the polymer in aprotic solvents. The highest solubility is observed at the concentration of PP 50 mol.%. It is found that reduced viscosity of cardo polymer solutions leads to an increase in the coagulation rate. The permeance of asymmetric ultrafiltration membranes increases with PP concentration from 17.5 L/(m2·h·bar) (10 mol.% PP) to 85.2 L/(m2·h·bar) (90 mol.% PP). These data are in agreement with the results of a study of the coagulation rate of polymer solutions. Thus, for ultrafiltration membranes with 1.5-8 times higher permeance in comparison with PPSU due to the introduction of cardo fragments in the polymer chain, possessing high rejection of the model dye Blue Dextran (MW = 70,000 g/mol), more than 99.2%, as well as high strength characteristics, were achieved.

Modeling the Ultrasonic Micro-Injection Molding Process Using the Buckingham Pi Theorem

Dimensional analysis through the Buckingham Pi theorem was confirmed as an efficient mathematical tool to model the otherwise non-linear high order ultrasonic micro-injection molding process (UMIM). Several combinations of processing conditions were evaluated to obtain experimental measurements and validate the derived equations. UMIM processing parameters, output variable energy consumption, and final specimen's Young modulus were arranged in dimensionless groups and formulated as functional relationships, which lead to dimensionless equations that predict output variables as a function of the user-specified processing parameters and known material properties.

Numerical Simulation on the Acoustic Streaming Driven Mixing in Ultrasonic Plasticizing of Thermoplastic Polymers

The acoustic melt stream velocity field, total force, and trajectory of fluorescent particles in the plasticizing chamber were analyzed using finite element simulation to investigate the acoustic streaming and mixing characteristics in ultrasonic plasticization micro-injection molding (UPMIM). The fluorescence intensity of ultrasonic plasticized samples containing thermoplastic polymer powders and fluorescent particles was used to determine the correlation between UPMIM process parameters and melt mixing characteristics. The results confirm that the acoustic streaming driven mixing occurs in ultrasonic plasticization and could provide similar shear stirring performance as the screw in traditional extrusion/injection molding. It was found that ultrasonic vibrations can cause several melt vortices to develop in the plasticizing chamber, with the melt rotating around the center of the vortex. With increasing ultrasonic amplitude, the melt stream velocity was shown to increase while retaining the trace, which could be altered by modulating other parameters. The fluorescent particles are subjected to a two-order-of-magnitude stronger Stokes drag force than the acoustic radiation force. The average fluorescence intensity was found to be adversely related to the distance from the sonotrodes' end surface, and fluorescence particles were more equally distributed at higher parameter levels.

Photoaging of Baby Bottle-Derived Polyethersulfone and Polyphenylsulfone Microplastics and the Resulting Bisphenol S Release

This study evaluated the release of bisphenol S (BPS) from polyethersulfone (PES) and polyphenylsulfone microplastics (MPs) derived from baby bottles under UV irradiation. Released BPS fluctuates over time because it undergoes photolysis under UV₂₅₄ irradiation. Under UV₃₆₅ irradiation, the highest released concentration at 50 °C was 1.7 and 3.2 times that at 35 and 25 °C, respectively, as the activation energy of the photochemical reactions responsible for MP decay was reduced at high temperatures. Low concentrations of humic acid (HA, ≤10 mg·L^-1) promote BPS release because HA acts as a photosensitizer. A high concentration of HA (10∼50 mg·L^-1) decreases the BPS release because HA shields MPs from light and scavenges reactive radicals that are produced via photochemical reactions. For example, under UV irradiation, hydroxyl radicals (•OH) attack results in the breakage of ether bonds and the formation of phenyl radicals (Ph•) and phenoxy radicals (Ph-O•).The•OH addition and hydrogen extractions further produce BPS from the decayed MPs. A leaching kinetics model was developed and calibrated by the experimental data. The calibrated model predicts the equilibrium level of BPS release from MPs that varies with the surface coverage density of BPS and leaching rate constants. This study provides groundwork that deepens our understanding of environmental aging and the chemical release of MPs.

Tuning Power Ultrasound for Enhanced Performance of Thermoplastic Micro-Injection Molding: Principles, Methods, and Performances

With the wide application of Micro-Electro-Mechanical Systems (MEMSs), especially the rapid development of wearable flexible electronics technology, the efficient production of micro-parts with thermoplastic polymers will be the core technology of the harvesting market. However, it is significantly restrained by the limitations of the traditional micro-injection-molding (MIM) process, such as replication fidelity, material utilization, and energy consumption. Currently, the increasing investigation has been focused on the ultrasonic-assisted micro-injection molding (UAMIM) and ultrasonic plasticization micro-injection molding (UPMIM), which has the advantages of new plasticization principle, high replication fidelity, and cost-effectiveness. The aim of this review is to present the latest research activities on the action mechanism of power ultrasound in various polymer micro-molding processes. At the beginning of this review, the physical changes, chemical changes, and morphological evolution mechanism of various thermoplastic polymers under different application modes of ultrasonic energy field are introduced. Subsequently, the process principles, characteristics, and latest developments of UAMIM and UPMIM are scientifically summarized. Particularly, some representative performance advantages of different polymers based on ultrasonic plasticization are further exemplified with a deeper understanding of polymer–MIM relationships. Finally, the challenges and opportunities of power ultrasound in MIM are prospected, such as the mechanism understanding and commercial application.

Manufacturing PLA/PCL Blends by Ultrasonic Molding Technology

Ultrasonic molding (USM) is a good candidate for studying the plasticization of polymer mixtures or other composite materials due to either the little amount of material needed for processing, low waste or the needed low pressure and residence time of the mold. Thus, the novelty of this research is the capability of USM technology to process PLA/PCL blends and their corresponding neat materials, encompassing all the production stages, from raw material to the final specimen. The major findings of the work revealed that the thermal properties of the blends were not affected by the USM process, although the crystallinity degree experienced variations, decreasing for PLA and increasing for PCL, which was attributed to the crystallization rate of each polymer, the high process speed, the short cooling time and the small particle size. The employed ultrasonic energy increased the molecular weight with low variations through the specimen. However, the degradation results aligned with the expected trend of these material blends. Moreover, this study also showed the effect pellet shape and dimensions have over the process parameters, as well as the effect of the blend composition. It can be concluded that USM is a technology suitable to successfully process PLA/PCL blends with the correct determination of process parameter windows.

Ultrasonic nodal point, a new configuration for ultrasonic moulding technology

Ultrasonic moulding is a new technology that uses high power ultrasound to melt and mould thermoplastic polymers to produce samples with mini and micro features. The main feature of this technology is the use of ultrasonic energy as the heating source instead of a conventional injection screw. Even if ultrasonic moulding overcomes some of the drawbacks of conventional mini and micro-injection moulding, it still presents two main limitations that are hindering its widespread applicability: the lack of stability of the process and the difficulty to obtain samples with good mechanical properties for some materials. This article presents a new configuration, called nodal point ultrasonic moulding (NPUSM), to surmount such limitations. This configuration improves the stability of ultrasonic moulding technology and it is capable of processing materials with good mechanical properties. To prove its efficacy, the nodal point ultrasonic moulding configuration is used to obtain the processing window of a polyoxymethylene material and these results are compared with standard ultrasonic injection and conventional injection moulding. The results obtained show that NPSUM configuration improves the capabilities of ultrasonic moulding technologies.

3D printing of dental restorations: Mechanical properties of thermoplastic polymer materials

In the seminal field of 3D printing of dental restorations, the time and cost saving manufacturing of removable and fixed dental prostheses from thermoplastic polymer materials employing fused filament fabrication (FFF) is gaining momentum. As of today, the additive manufacturing of the established semi-crystalline polyetheretherketone (PEEK) requires extensive post-processing and lacks precision. In this context, the amorphous polyphenylene sulfone (PPSU) may provide a higher predictability and reliability of the results. The aim of this study was to investigate the mechanical properties of PPSU and PEEK processed by FFF (PPSU1-3D (PPSU Radel) and PPSU2-3D (Ultrason P 3010 NAT)) or extrusion (PPSU1-EX (Radel R-5000 NT) and PEEK-CG (PEEK Juvora)). Three-point flexural strength, two-body wear, and Martens hardness (HM) and indentation modulus (E_IT) were tested after aging. One-way ANOVA, the Kruskal-Wallis and the Pearson's and Spearman's correlation tests were computed (α = 0.05). PPSU1-3D and PPSU2-3D showed lower flexural strength values than PPSU1-EX and PEEK-CG. PPSU1-3D showed the highest, and PEEK-CG and PPSU1-EX the lowest height loss. The highest HM and E_IT results were observed for PEEK-CG and the lowest for PPSU1-3D. Correlations were observed between all parameters except for the application height. In conclusion, the manufacturing process affected the flexural strength of PPSU, with 3D printed specimens presenting lower values than specimens cut from prefabricated molded material. This finding indicates that the 3D printing parameters employed for the additive manufacturing of PPSU specimens in the present investigation require further optimization. For 3D printed specimens, the quality of the filament showed an impact on the mechanical properties, underlining the importance of adhering to high quality standards during filament fabrication. Extruded PPSU led to comparable results with PEEK for flexural strength and two-body wear, indicating this novel dental restorative material to be a suitable alternative to the established PEEK for the manufacturing of both removable and fixed dental prostheses.

Fabrication of Micro Ultrasonic Powder Molding Polypropylene Part with Hydrophobic Patterned Surface

Constructing regular micro-structures with certain geometric characteristics on the surface of the polymer part can obtain some specific functions. Micro ultrasonic powder molding (micro-UPM) is an efficient processing technique for the fabrication of well-filled micro-structured Polypropylene (PP) parts. The micro-structure array on the surface of the core insert was obtained by low speed wire electrical discharge machining (WEDM-LS). PP polymer surfaces with micro-structured patterns were successfully replicated from the core insert surface after micro-UPM. By studying the detailed topography characterizations of micro-structured PP parts, the effects of processing parameters (ultrasonic energy, welding pressure and holding time) on the micro-structured filling show that when PP polymer was formed under the conditions of 1000 J, 115 kPa and 8 s during micro-UPM, well-filled micro-structured parts can be obtained. Besides, without low surface energy coating modification, the water contact angles (WCAs) of micro-structured PP parts increased from 85.3° to 146.8°, indicating that the wettability of the surface can be changed by replicating the micro-structure on PP parts after micro-UPM.

Ultrasonic moulding: Current state of the technology

Ultrasonic moulding, also known as ultrasonic microinjection moulding, is a new technology that uses high-power ultrasound to melt and mould thermoplastic polymers to produce samples with mini- and micro-features. The main feature of this technology is the use of ultrasonic energy as the heating source instead of a conventional injection screw. Since 2002, several authors have experimentally and theoretically studied the ability of ultrasonic energy to mould polymers. However, different machine configurations and experimental design strategies have been used, which makes it very difficult to compare the results obtained from different articles. In this report, the authors have compiled experimental studies on the ultrasonic moulding process and analysed them along with providing a theoretical framework. An accurate description of the process and the machine configurations used in the literature is also presented. The results obtained from the analysis are summarized and discussed, and possible next steps to further the research in this field are suggested.

Evolution of Interfacial Friction Angle and Contact Area of Polymer Pellets during the Initial Stage of Ultrasonic Plasticization

Interfacial friction heating is one of the leading heat generation mechanisms during the initial stage of ultrasonic plasticization of polymer pellets, which has a significant influence on the subsequent viscoelastic heating according to our previous study. The interfacial friction angle and contact area of polymer pellets are critical boundary conditions for the analysis of interfacial frictional heating of polymer pellets. However, the duration of the interfacial friction heating is extremely short in ultrasonic plasticization, and the polymer pellets are randomly distributed in the cylindrical barrel, resulting in the characterization of the distribution of the interfacial friction angle and contact area to be a challenge. In this work, the interfacial friction angle of the polymer pellets in the partially plasticized samples of polymethyl methacrylate (PMMA), polypropylene (PP), and nylon66 (PA66) were characterized by a super-high magnification lens zoom 3D microscope. The influence of trigger pressure, plasticizing pressure, ultrasonic amplitude, and vibration time on the interfacial friction angle and the contact area of the polymer pellets were studied by a single factor experiment. The results show that the compaction degree of the plasticized samples could be enhanced by increasing the level of the process parameters. With the increasing parameter level, the proportion of interfacial friction angle in the range of 0–10° and 80–90° increased, while the proportion in the range of 30–60° decreased accordingly. The proportion of the contact area of the polymer pellets was increased up to 50% of the interfacial friction area which includes the upper, lower, and side area of the cylindrical plasticized sample.

Ultrasonic Molding Technology: Recent Advances and Potential Applications in the Medical Industry

Recently, ultrasonic molding (USM) has emerged as a promising replication technique for low and medium volume production of miniature and micro-scale parts. In a relatively short time cycle, ultrasonic molding can process a wide variety of polymeric materials without any noticeable thermal degradation into cost-effective molded parts. This research work reviews recent breakthroughs of the ultrasonic injection molding and ultrasonic compression molding process regarding the equipment and tooling development, materials processing and potential applications in the medical industry. The discussion is centered on the challenges of industrializing this technology, pointing out the need for improvement of the current process’s robustness and repeatability. Among the most important research areas that were identified are the processing of novel engineered and nanomaterials, the understanding and control of the ultrasonic plasticization process and the tooling and equipment development.

Characterization of the Fluidity of the Ultrasonic Plasticized Polymer Melt by Spiral Flow Testing under Micro-Scale

The fluidity of a molten polymer plasticized by ultrasonic vibration was characterized by spiral flow testing based on an Archimedes spiral mold with microchannels. Mold inserts with various channel depths from 250 to 750 µm were designed and fabricated to represent the size effect under micro-scale. The effect of ultrasonic plasticizing parameters and the mold temperature on the flow length was studied to determine the rheological nature of polymers and control parameters. The results showed that the flow length decreased with reduced channel depth due to the size effect. By increasing ultrasonic amplitude, ultrasonic action time, plasticizing pressure, and mold temperature, the flow length could be significantly increased for both the amorphous polymer polymethyl methacrylate (PMMA) and the semi-crystalline polymers polypropylene (PP) and polyamide 66 (PA66). The enhanced fluidity of the ultrasonic plasticized polymer melt could be attributed to the significantly reduced shear viscosity.