Identifying Structure-Property Relationships of Micro-Architectured Porous Scaffolds through 3D Printing and Finite Element Analysis

This study integrates 3D printing and finite element analysis (FEA) to investigate the effect of micro-architectural characteristics on the mechanical properties of porous scaffolds. The studied characteristics include the thickness of the scaffold walls and the number of domains at the cross-section. We use 3D printing to fabricate scaffolds of deliberately designed microstructures to enable strict control of the structures. The longitudinal compressive properties of different scaffolds are first analyzed through experimental testing. Then, FEA is conducted to investigate the mechanical properties and the deformation mechanisms of the scaffolds. We find that decreasing wall thickness leads to failure mechanism transition from wall compression failure to buckling instability. For scaffolds with different wall thicknesses, the failure mechanisms and the critical loads are evaluated using the theory of thin plate buckling. For the characteristic of the number of domains, both experimental and FEA results indicate increasing effective stiffness with increasing domains. Interestingly, we find that with the material properties extracted from a single wall scaffold, the computational models tend to overestimate the effective compression modulus of scaffolds with larger numbers of walls or domains than the experimental data. This observation indicates possible size-dependent material properties in 3D printed structs. Our study demonstrates that integrating experiments and computational modeling can provide fundamental insights into the mechanical properties and deformation mechanisms of micro-architectured scaffolds and unveil unique small-scale material behaviors.

Preparation and properties of silicone rubber materials with foam/solid alternating multilayered structures

In this paper, silicone rubber materials with foam/solid alternating multilayered structures were successfully constructed by combining the two methods of multilayered hot-pressing and supercritical carbon dioxide (SCCO2) foaming. The cellular morphology and mechanical properties of the foam/solid alternating multilayered silicone rubber materials were systematically studied. The results show that the growth of the cell was restrained by the solid layer, resulting in a decrease in the cell size. In addition, the introduction of the solid layer effectively improved the mechanical properties of the microcellular silicone rubber foam. The tensile strength and compressive strength of the foam/solid alternating multilayered silicone rubber materials reached 5.39 and 1.08 MPa, which are 46.1% and 237.5% of the pure silicone rubber foam, respectively. Finite element analysis (FEA) was applied and the results indicate that the strength and proportion of the solid layer played important roles in the tensile strength of the foam/solid alternating multilayered silicone rubber materials. Moreover, the small cellular structures in silicone rubber foam can provided a high supporting counterforce during compression, meaning that the microcellular structure of silicone rubber foam improved the compressive property compared to that for the large cellular structure of silicone rubber foam.

Adjustable polystyrene nanoparticle templates for the production of mesoporous foams and ZnO inverse opals

The manifold applications of porous materials, such as in storage, separation, and catalysis, have led to an enormous interest in their cost-efficient preparation. A promising strategy to obtain porous materials with adjustable pore size and morphology is to use templates exhibiting the appropriate nanostructure. In this study, close-packed polystyrene (PS) nanoparticles, synthesized by emulsion polymerization, were used to produce porous PS and ZnO inverse opals. The size and distribution of the polystyrene nanoparticles, characterized by dynamic light scattering (DLS), small-angle neutron scattering (SANS), and scanning electron microscopy (SEM), were controlled via the concentration of sodium dodecyl sulfate (SDS). Systematic measurements of the water/styrene-interfacial tension show that the critical micelle concentration (CMC) of the ternary water–styrene–SDS system, which determines whether monodisperse or polydisperse PS particles are obtained, is considerably lower than that of the binary water–SDS system. The assemblies of close-packed PS nanoparticles obtained via drying were then studied by small-angle X-ray scattering (SAXS) and SEM. Both techniques prove that PS nanoparticles synthesized above the CMC result in a significantly unordered but denser packing of the particles. The polystyrene particles were subsequently used to produce porous polystyrene and ZnO inverse opals. While the former consists of micrometer-sized spherical pores surrounded by extended open-cellular regions of mesopores (Rpore ≈ 25 nm), the latter are made of ZnO-nanoparticles forming a structure of well-aligned interconnected pores.

Foams with Enhanced Ductility and Impact Behavior Based on Polypropylene Composites

In this work, formulations based on composites of a linear polypropylene (L-PP), a long-chain branched polypropylene (LCB-PP), a polypropylene-graft-maleic anhydride (PP-MA), a styrene-ethylene-butylene-styrene copolymer (SEBS), glass fibers (GF), and halloysite nanotubes (HNT-QM) have been foamed by using the improved compression molding route (ICM), obtaining relative densities of about 0.62. The combination of the inclusion of elastomer and rigid phases with the use of the LCB-PP led to foams with a better cellular structure, an improved ductility, and considerable values of the elastic modulus. Consequently, the produced foams presented simultaneously an excellent impact performance and a high stiffness with respect to their corresponding solid counterparts.

Measurement of the Young’s modulus and shear modulus of extruded polystyrene foam by the longitudinal and flexural vibration methods

The Young’s modulus and shear modulus of extruded polystyrene foam were obtained by measurements using the longitudinal and flexural vibration methods on specimens with various lengths and performing a subsequent numerical analysis on the test data. In addition to the vibration tests, ISO 844 compression and ASTM C273/C273M-11 shear tests were conducted, and the results were compared with those obtained from the vibration tests. The Young’s modulus values could be measured accurately by the longitudinal and flexural vibration tests while reducing the effects of the specimen configuration. In contrast, the shear modulus value was often dependent on the specimen configuration. The Young’s modulus and shear modulus values obtained from the vibration tests were often higher than those obtained from the standardised tests because the bending of cell wall is not induced in the vibration test. Although a provisional method for reducing the influence of the specimen configuration was proposed based on the numerical results, further research is required to measure the elastic modulus of extruded polystyrene foam accurately.

Complex cellular structure evolution of polystyrene/poly (ethylene terephthalate glycol-modified) foam using a two-step depressurization batch foaming process

In order to decrease the cell size and maintain very high volume expansion ratio simultaneously, a methodology for the preparation of complex cellular structure (CCS) in polystyrene/poly(ethylene terephthalate glycol-modified) (PS/PETG) blend using two-step depressurization pressure batch foaming process was proposed. First, the optimum foaming temperature for PS and PS/PETG blend, respectively, were confirmed by one-step depressurization foaming process. Then, the CCS in PS and PS/PETG blending foam were fabricated by two-step depressurization foaming process at the optimum foaming temperature. The rheological properties of PS and PS/PETG blend were tested by dynamic rotational rheometer. The dispersion morphologies and foam morphologies were observed by scanning electron microscope. The lowest densities of PS and PS/PETG blending foams were obtained at the temperature of 136℃. The interfaces between PS and PETG could act as nucleation sites for the cell nucleation, which were helpful to fabricate the CCS. The CCS could be controlled by tuning the degree of the first-step depressurization and the holding time. The results showed that the large cells could be beneficial to decrease the foam density and the presence of small cells was beneficial to increase the cell number.

Asymmetric microcellular composites: Mechanical properties and modulus prediction

In the first part of this study, asymmetric microcellular composites were prepared by injection molding to study their morphological properties as a function of temperature gradient inside the mold (0–60℃), as well as foaming agent (0–1%) and natural fiber (0–30%) contents. High-density polyethylene, flax fiber, and azodicarbonamide were used for the matrix, reinforcement, and chemical blowing agent, respectively. From the samples produced, mechanical properties (tensile, flexion, torsion, impact) are analyzed in this second part. Mechanical properties were found to be strongly influenced by density reduction and natural fiber content. It was also found that fiber addition provides higher reinforcement in flexion than torsion and tension. Also, flexural modulus and impact strength were relatively unaffected by foaming agent content for the range of parameters studied. From the experimental data obtained, a simple mechanical model based on density profile is presented to predict the elastic moduli of asymmetric structural composite foams.

Mechanical and dielectric properties of microcellular polycarbonate foams with unimodal or bimodal cell-size distributions

This article reports on the compressive, dynamic mechanical and dielectric properties of microcellular polycarbonate foams with unimodal or bimodal cell-size distributions fabricated using the environment-friendly supercritical carbon dioxide. The effects of cell morphologies such as relative density, cell-size distribution and porosity on the compressive strength, Young’s modulus, storage modulus, loss modulus, dielectric constant and loss tangent of the microcellular polycarbonate foams are investigated quantitatively. Experimental values of the compressive strength and Young’s modulus fit very well with the theoretical values calculated from the Gibson–Ashby model at low relative densities. The higher relative density leads to higher storage modulus and loss modulus. The bimodal foams significantly improve the compressive and dynamic mechanical properties compared to the unimodal foams with the same relative density. The dielectric properties of microcellular foams depend only on the total porosity, but not on the cell-size distribution or microstructure of the foams. With increasing porosity, the dielectric constant of the microcellular foams gradually decreases, and agrees very well with the curve calculated from the Maxwell-Garnett-spheres model.