An Investigation to Reduce the Effect of Moisture on Injection-Molded Parts through Optimization of Plasticization Parameters

Comparative Analysis of Impact Strength among Various Polymeric Materials for Orthotic Production

Orthotic devices play an important role in medical treatment, addressing various pathologies and promoting patient recovery. Customization of orthoses to fit individual patient morphologies and needs is essential for optimal functionality and patient comfort. The advent of additive manufacturing has revolutionized the biomedical field, offering advantages such as cost reduction, increased personalization, and enhanced dimensional adaptability for orthotics manufacturing. This research focuses on the impact strength of nine polymeric materials printed by additive manufacturing, including an evaluation of the materials' performance under varying conditions comprising different printing directions (vertical and horizontal) and exposure to artificial sweat for different durations (0 days, 24 days, and 189 days). The results showed that Nylon 12 is good for short-term (24 days) immersion, with absorbed energies of 78 J and 64 J for the vertical and horizontal directions, whereas Polycarbonate (PC) is good for long-term immersion (189 days), with absorbed energies of 66 J and 78 J for the vertical and horizontal directions. Overall, the findings contribute to a better understanding of the suitability of these materials for biomedical applications, considering both short-term and long-term exposure to physiological and environmental conditions.

Novel Method for Failure Modes Detection in UV-Cured Clear Coated Polymer for Automotive Interior Mechatronic Devices

Plastic parts used in automotive interior are difficult to coat, due to their low surface energies as well as their sensitivity to temperature and solvents, rendering the development of coating systems for such substrates challenging. Automotive customer requirements are explicit and clear, mainly focused on functional and surface defects. A new failure modes detection methodology of UV clear coated polymers for automotive interior, obtained by a multi-step manufacturing process, is proposed. The polymer complex parts analyzed in this paper are manufactured in various steps as follows: two components plastic injection molding, primer coating, laser engraving, and UV-cured clear coating. The failure modes detection methodology of the parts within each process step is investigated using different tests and analyses as follows: surface tension test, painting adhesion test, optical 3D measuring, energy dispersive X-ray analysis (EDX), and microscopy. A design of the experiments (DoE) based on the Taguchi technique with the aim to detect the influence of the main factors that lead to surface defects was performed. The proposed methodology is validated by a case study. The results showed that the mold temperature and the laser engraving current have a significant influence on the surface defect occurrence. Additionally, a possible contamination of the molding tool can generate the defects. A solution to reduce the occurrence of the failures was proposed, reducing the defect rate from 50% to 0.9%.