Abstract

TBA

About the Presenter

Dr. Christian Hopmann holds the Chair for Plastics Processing and is director of the IKV - Institute for Plastics Processing in Industry and Crafts at RWTH Aachen University in Germany. He is as well co-founder of the AZL - Aachen Center for Lightweight Production and Vice Dean of the faculty for Mechanical Engineering of RWTH Aachen University. His interest is fundamental and applied research in plastics technology with particular focus on Digitization and Simulation, Lightweight Technologies and Circular Economy. Hopmann is principal investigator and member of the steering committee of the Federal Cluster of Excellence “Internet of Production”. He initiated the Polymer Innovation Center 4.0, which addresses the domain specific realization and implementation of digitization in the plastics industry with particular focus on SME.

After studying mechanical engineering, he received his doctoral degree from RWTH Aachen University. Following a senior vice-director position at IKV, he started his industrial career in 2005 at the plastics processing company RKW SE, latterly as Managing Director of RKW Sweden A.B. in Helsingborg/Sweden. He participated in the Program for Executive Development at the International Institute for Management Development (IMD) in Lausanne, Switzerland. Hopmann received the Innovation Award of Germany's federal state North Rhine-Westphalia in 2014. He has been appointed visiting professor at the Beijing University of Chemical Technology, Beijing/China in 2017 and fellow of the Society of Plastics Engineers, CT/USA, in 2019. Hopmann serves as international representative of the Polymer Processing Society since 2021 and is member of the board of directors and the scientific advisory board as well as chairman of the board of the material engineering division of the VDI - The Association of German Engineers since 2022.

Abstract

Recycling commodity resins such as polyethylene, poly(vinyl chloride), and poly(ethylene terephthalate) is critical for meeting global sustainability goals. A current initiative involves developing critical testing and quality control methods for post-consumer and post-industrial recycling of poly(vinyl chloride) (PVC). PVC is ubiquitous, with waste generated from vinyl siding and other building materials, wire coatings, plastic pipe and conduit, films and packaging. For PVC, methods for torque rheometry and extrusion capillary viscometry have been developed specifically for process development and quality control testing of recycled PVC to ensure that these critical materials become part of manufacturing feedstocks resulting in cost-effective products rather than waste occupying landfills and waterways. Results show significant lot-to-lot variations of feedstocks, including broad ranges of torque — temperature behavior, and observation of various phases within a sample, as confirmed with differential scanning calorimetry (DSC), as well as large swings in thermal stability. By targeting various sources for specific industries and reforming some recycled PVC through addition of stabilizers and other additives, a greater percentage of waste PVC can be reused.

About the Presenter

With over 20 years of experience in polymer materials and process development, Shane Harton is the North American Sales Manager for C.W. Brabender Instruments, Inc. in South Hackensack, NJ. He has a B.S. in Chemical Engineering from Penn State and a PhD in Materials Science from N.C. State and has published over 20 articles in the field of polymer physics, with topics ranging from polymers under to confinement to the molecular structure of naturally-occurring polymers. He also holds several patents on novel membrane technologies.

Brabender is celebrating 100 years of innovation with its dedication to manufacturing, engineering, science and technology.

Abstract

The use of graphene nanoplatelets (GnP), biochar from agricultural waste, basalt fibers, graphite and wool from recycled sources and micro and nanoscale boron compounds as reinforcing and antimicrobial additives for different polymer matrices was studied. The recyclability of basalt fiber and natural fiber reinforced polypropylene (PP) and polyamide (PA6) composites were studied through injection molding and mechanical grinding. Flexural, tensile, and impact tests were conducted to assess the degradation in mechanical properties of virgin and recycled composites. The polymer matrices were exposed to many different chemical and physical environments to see the effect of environmental exposure (UV, temperature, humidity, sweat, abrasion) and active chemical ingredients in sunscreen lotions and insect repellents on the final antimicrobial efficacy of the polymer matrix. Compared to control samples, the modulus of elasticity increased with GnP, biochar, and boron compounds. An improvement in antimicrobial activity was observed with a combination of disodium octaborate tetrahydrate and zinc pyrithione content. Thermal stability also improved with the increasing GnP and boron compounds concentration.

About the Presenter

Dr. Iyigundogdu has been an Assistant Professor at the Department of Bioengineering of Adana Science and Technology University since 2016. In 2013, she earned her Ph.D. from the integrated doctorate program of Chemical Engineering at Yeditepe University in Istanbul, Turkey. She completed her studies in collaboration with the Bioengineering Department. Her current research interests are developing antimicrobial/antiviral materials, antimicrobial formulations, green synthesis of magnetic nanoparticles, boron ores, zeolites, and biomaterials.

Abstract

Dry stereolithography is a new and patented process that uses thermoplastic photopolymers in film or sheet/plate form instead of liquid photopolymer resins and does not require support structures during the built process. The process generally relates to the use of dry photopolymers to make a 3D printed object formed from individually and selectively exposed dry photopolymer layers of the same or gradually varying shape. The nature of these new raw materials for 3D printing will be discussed. Steps in the printing process will be described. Suggested markets for dry stereolithography will be outlined. Photopolymer plates/sheets/films as raw materials are environmentally friendly.

About the Presenter

Manilal Savla has worked as a scientist and a researcher in the field of polymers/plastics for more than five decades. He is an emeritus member of SPE. He has five US patents and one Indian patent to his credit and has written scores of publications including book chapters and magazine columns published in the US, India, UK and Germany. His last US patent entitled Stereolithography with Thermoplastic Photopolymers was granted in July 2021.

Abstract

Effect of polybutylene succinate on the isothermal crystallization kinetics of polylactic acid Milad Azami, Amir Ameli University of Massachusetts Lowell, Department of Plastics Engineering, 1 University Ave, Lowell MA, 01854 Recently, biodegradable polymers which are also derived from renewable sources are becoming essential to replace fossil fuel-based commodity polymers in fibers and textile applications. Polylactic acid (PLA) is a plant-based polymer and one of the promising biodegradable alternatives to replace polypropylene in fibrous applications due to its composability and reliable mechanical properties. However, PLA is a brittle polymer with slow crystallization kinetics. Blending it with more ductile polymers is a reliable strategy to overcome the brittleness of PLA. Polybutylene succinate (PBS), another biodegradable polyester can enhance the ductility of PLA, especially in melt-spinning applications such as spun bound, however, deeper studies are required to evaluate the effect of PBS on the crystallization kinetics of PLA. In this study, PLA was melt-blended with PBS in several ratios varying from 5 wt.% to 20 wt.% using a micro-compounder. The same processing conditions were applied to all the compositions as well as control PLA and PBS. Isothermal differential scanning calorimetry (DSC) tests at 85°C, 100°C, and 115 °C as well as non-isothermal heat-cool-heat tests were carried out. The isothermal crystallization and the Avrami model results showed that the total amount of crystalline domains in the PLA phase increased up to 50% at the presence of PBS. However, the crystallization kinetics of PLA was delayed quite significantly. This study suggests the use of a proper nucleating agent to benefit both ductility and crystallinity of PLA/PBS blends in fibrous applications.

About the Presenter

Milad joined the Ph.D. program of UMass Lowell Plastics engineering department in January 2020, he obtained his Master and bachelor's degree in chemical engineering from the university of Tabriz in Iran. His current research focuses on Biodegradable polymer blends and additive manufacturing.

Abstract

Plastic production continues to increase and is expected to surpass more than 900 million tonnes in 2050. Plastic recycling has become necessary to provide correct disposal for this material to avoid landfill accumulation or, even worse, ending up in rivers and oceans. Plastic pollution is a global issue with further research and understanding needed to increase recycling rates. One essential approach to increase recycling rates is to evaluate the composition of outbound streams from current recycling facilities and what capacity they can be reused. In this study, the composition and quality of outbound bales containing #3-7 plastics destined to landfill or waste-to-energy facilities were assessed to understand the potential to increase recycling rates. Bales were sourced from three different Material Recovery Facilities (MRFs) located in the states of Iowa and Wisconsin and were manually sorted and analyzed using multiple plastic characterization techniques. Significant differences in bale composition were observed between MRFs, usually associated with the sophistication level or technology used in the sorting process with seasonal feedstock variability. Differences were substantial in residual levels of poly(ethylene terephthalate) (PET) and high-density polyethylene (HDPE), which are highly desired for mechanical recycling processes and not expected to be present in #3-7 plastics bales. Prior to physical, thermal, and molecular characterization on recovered PET, HDPE, low-density polyethylene (LDPE), polypropylene (PP), and polystyrene (PS) resins, traditional mechanical recycling processes were employed to include washing, extrusion, and injection molding of sorted material. Despite the differences in composition, some polymer properties presented similar values across MRFs. This research suggests that landfill-diverted mixed plastic waste can be utilized for novel and advanced recycling operations to recover unrecycled materials as processes can be designed to provide consistent polymer properties. This research also suggests the need for upgrading the sorting systems to prevent waste feedstocks that can be recycled with current technologies from ending up with low-value products or at landfills.

About the Presenter

Victor received his Bachelor's degree in Chemical Engineering from the Federal University of Sao Carlos (UFSCar, Brazil) in 2019 and is currently pursuing a Ph.D. in Food Science and Technology at Iowa State University under the supervision of Dr. Keith Vorst. During his undergraduate studies, he was a visiting scholar at the University of British Columbia (UBC, Canada) for one year and an R&D intern for 1.5 years at 3M Brazil. His research focuses on the mechanical and chemical recycling of landfill-diverted mixed plastic waste with the use of several polymer processing and characterization techniques, as part of the efforts of the Chemical Upcycling of Waste Plastics (CUWP) center.

Abstract

Everyone builds portfolio of methods to handle bothersome difficulties when dealing with measurement of the flow properties of polymer melts. Most of these methods are never published, which is unfortunate, while others are buried in the Experimental section of a paper and thus difficult to locate. In this presentation, some of my own unpublished — or less published — methods will be presented and discussed. Examples include a really cheap, vacuum stress relaxometer for elastomers, a method for determining the flow curve of a thermosetting resin using a capillary rheometer, a desktop method of determining the viscosity of aqueous polymer solutions, and a simple trick for running a constant-stress extensional flow experiment of a polymer melt. In addition, two other methods of measuring the extensional flow properties of polymer melts will be described. Finally, several simple analysis methods will be reviewed including a modification of the Cross-Kaye ¬æth rule for single-point analysis of parallel-plate data, kink-point detection, T-t analysis of non-overlapping data, and the concept of random frequency sweeps.

About the Presenter

Montgomery T. Shaw Department of Chemical and Biomolecular Engineering University of Connecticut
(a)Professional Preparation

• Cornell University, Chemical Engineering, B.Ch.E., June 1966; M. S., June 1966
• Princeton University, Chemistry, M. A., June 1968
• Princeton University, Chemistry; Ph.D., August 1970

(b)Appointments

• Emeritus Professor, June 2009 — present
• Interim Dept. Head, Chemical, Materials and Biomolecular Engr., July 2007 — June 2008
• T. DiBenedetto Distinguished Engineering Professor, October 2002 — June 2009
• Professor of Chemical Engineering, University of Connecticut, August 1983 — June 2009
• Visiting Scientist, DuPont Experimental Station, Wilmington DE, August 1991 — June 1992
• Sabbatical Professor, Sandia National Laboratories, Albuquerque, July 1983 — June 1984
• Associate Professor, University of Connecticut, January 1977 — July 1983
• Research and Development Staff, Union Carbide Corporation, Bound Brook, NJ, August 1970 — December 1976

(c)Research Interests/Accomplishments

Interests in polymer rheology and processing, including thermodynamics and processing of polymer blends and liquid crystal polymers, proton exchange membranes using field alignment, mechanism of so-called sharkskin melt fracture, biodegradable composites for bone repair. (d) Selected awards and honors Tau Beta Pi; Phi Kappa Phi; Phi Eta Sigma; Secretary of the Society of Rheology, 1977 81, Treasurer, 1997-2015; Best Paper Award, SPE RETEC, 1988 and SPE ANTEC, 2005; Assoc. Editor, IEEE Transactions on Dielectrics and Electrical Insulation, 1991-2013; International Research Award, SPE, 1998, Distinguished Engineering Professor, 1999; SPE Fellow, 2000; International Award, SPE, 2002; A. T. DiBenedetto Distinguished Engineering Professor, 2002; SPE-PAD Founders' Award, 2004; Connecticut Academy of Science and Engineering, 2004; Service Award, Society of Rheology, 2017; Fellow, The Society of Rheology.

Abstract

Mass Spectrometry (MS) has become an indispensable tool for polymer analysis and has been widely used to study polymer structure and composition, end-groups and additives, molecular weight distribution, degree of polymerization, and so on. MS analysis is extremely sensitive, allowing the detection and identification of minor polymer components and synthesis by-products, as well as low-level impurities and products of decomposition. Matrix Assisted Laser Desorption Ionization (MALDI) MS is a well-established method of polymer characterization that continues to be developed and improved with new generations of MS instruments, bringing new analytical capabilities and enhanced performance. Modern MALDI-MS instruments generate rich chemical information highly specific for polymer structural analysis, copolymer composition and complex polymer mixtures characterization, and can even be used for imaging of synthetic polymer surfaces. Because of its unique capabilities, this technology has been widely used in a great variety of polymer analysis applications in both academic and industrial settings. In some cases, MALDI-MS is the only technique that can provide the information required to solve a practical problem. It allows for rapid MS analysis where no prior sample treatment or extensive separation is needed, including characterization of challenging insoluble polymers. TIMS technology has redefined the capabilities of Ion Mobility separation by providing an unmatched combination of resolution, speed, robustness and sensitivity. In polymer analysis applications, the timsTOF instruments expand the analytical boundaries by combining the TIMS technology with ultra-high-performance MS and providing an additional dimension for separation of complex polymer mixtures and structural analysis of challenging polymer compositions. Compatible with HPLS-ESI, GC-APCI and MALDI workflows, Bruker timsTOF fleX is a go-to multitool for a modern polymer lab.

About the Presenter

Mark Arnould is a senior applications scientist focused on polymer & industrial chemicals in Billerica. He earned his Ph.D. at the University of Akron in the Wesdemiotis group. Mark has over 20 years of experience in the analysis of synthetic macromolecules using MALDI-ToF mass spectrometry. Mark spent 3.5 years at Oak Ridge National Lab in the Center for Nanophase Materials Sciences conducting research and working with users on MALDI MS. Prior to that he worked at Xerox Corporation for 14 years as the polymer MALDI SME after completing an NRC post-doctoral appointment at the National Institute of Standards and Technology.

Abstract

We report using the coordinated silver (I) complex based on SIL in a toughened epoxy resin composite to enable electrical and thermomechanical properties. The toughened epoxy resin was aligned at the molecular level utilizing an electric field, demonstrating a relatively high electric conductivity, energy storage, and rapid curing behaviour that can save energy, reduce unnecessary heat, and optimize capital and operating costs. Applying Small Angle Neutron Scattering (SANS), our work thoroughly studied the effect of alignment changes on the silver (I) complex and AgNPs under an applied electrical field and assessed the stability of the alignment after the electric field was constantly removed. Furthermore, the in-situ SANS investigation of the kinetic effects under external impulse influence helped identify the clusters of Ag under an external electric field in various composite matrices. This technology can be used for accurate noninvasive blood circulation; increasing material electrical conductivity by applying induced electric field molecular alignment can tremendously increase sensor sensitivity. This approach opens the door to the next generation of thermoset polymers with multifunctional properties.

About the Presenter

I am naturally a problem solver and use this to my advantage in work. I research technologies associated with Industry 4.0, broadening and deepening capabilities to innovate solutions for complex business and industrial challenges. With many years of experience, I uniquely stand out as a Professional Engineer, Material and Data Scientist, Cloud Computing architect, and Management Consultant Executive, enabling digital transformation to unleash high performance.

Abstract

Multi-material additive manufacturing (AM) pushes the barriers of complex part production with a comprehensive and complementary material spectrum to unprecedented heights. The experimental "Fusion Jetting" technology is one of the first attempts to simultaneously process thermoplastics and thermosets within a single AM process to functional multi-material parts. Applications lie in the field of load-path optimized reinforcements, hard-soft and smart structures as well as the strategic variation of the mechanical, thermal, and electro-magnetic part properties. This investigation focuses on the implementation of UV-curable acrylates within thermoplastic polyurethane (TPU) parts to specifically alter the strength and elongation behavior of future parts. Process parameters like the laser power or the acrylate content within each plane are strategically varied to examine their respective impact on the mechanical and microscopic part properties. Based on tensile testing results, an increase of the Young's Modulus for continuous acrylate reinforcements parallel to the load path is detected. On a microscopic level, the choice of the processing sequence proofs fundamental towards the laser/material interaction and the infiltration behavior. This includes the detection of increased infiltration of the acrylate within melted regions of TPU using low energy densities. The results are further discussed towards the bonding behavior between the material constituents, including the potential impact of selected process parameters on the visually detected delamination behavior during mechanical testing.

About the Presenter

Robert Setter studied mechanical engineering at Technical University of Munich with majors in aerospace, light weight design and carbon fiber reinforced plastics. In 2017, he worked for 10 months as a visiting scholar in the field of resin-based additive manufacturing at the Polymer Engineering Center by Prof. Tim A. Osswald at the University of Wisconsin. In 2019, he wrote his master's thesis at BMW about additively manufactured injection molding polymer tools. Since March 2020, he is a research associate at the Professorship of Laser-based Additive Manufacturing by Prof. Dr.-Ing. Katrin Wudy at Technical University of Munich. He currently works in the field of innovative polymer-based additive manufacturing processes with a focus on powder- and resin-based technologies. This includes the conceptualization and development of new processes as well as the experimental analysis and characterization of polymer-based materials and additively manufactured parts.

Abstract

In addition to polymers based on non-fossil feedstocks that help reduce carbon footprint or blends that incorporate recycled content to reduce waste, there additional strategies a manufacturer can pursue to further lower energy consumption and material usage. In this presentation, we delve into polycarbonate materials chemistry and property profile to point out cases where the material and process innovations come together to maximize productivity and lower energy consumption or even lower material consumption to reduce waste. How these fit together in a greater context of plastics manufacturers looking to be part of an emerging circular economy will also be discussed.

About the Presenter

Plastics Engineering Technology graduate with experience in processing, design, manufacturing, research and development, and materials.

Abstract

One major problem of a continuous process like plastic extrusion is their incapability to deal with non-local gas pressure. This is an inherent problem because a continuous process's two "open ends" where pressure can escape. In this study a novel feeding system was developed to enable granulate feeding into gas pressurized processes inside a single- or twin-screw extruder. With this apparatus gas pressure can be applied inside the extrusion process. The apparatus separates the pressurized extruder from the dosing equipment that feeds the extruder. It keeps the pressure inside the system while continuously feeding new material into the process. The proposed prototype was designed around a square casing with two different sized holes perpendicular to each other. This creates a cross section in the middle which acts as a valve. On top is the inlet port and on the opposite site the outlet port. Both are radial sealing parts that adapt the curvature of the perpendicular hole. A crucial component of the prototype is the three-dimensional sealing that separates the two atmospheres. It had to be abrasion resistant as well as flexible enough to be installed at a curved contour. These requirements made it difficult to use traditional seals. Polytetrafluoroethylene (PTFE) is a polymer that is highly abrasion resistant and used in high pressure environments. It was used for this special three-dimensional seals to separate the two pressure atmospheres. Another challenge was the big difference in pressure, which led to a sudden pressurization of the feeding container. This meant that all granulate inside this container got scattered from the incoming pressure flow. Since the granulates are scattered, they could not fall down into the extruder. These problems were solved adding ventilation adapters for pressurizing and depressurizing. The first small-scale Prototype was made from aluminum and designed to be connected to pressured nitrogen. Due to the size of the prototype, it will be able to handle small amounts of granulates of around 10-20 kg/h. An applied gas pressure of 7 bar was achieved, with current optimization towards 15-20 bar. Following prototypes will be made of stainless steel demonstrate higher material throughput as an important next step in optimizing the feeding system. Main applications for this new feeding equipment could be foaming processes and reactive extrusion systems. In foaming applications, blowing agents could be injected earlier since the gas cannot escape at the feeding port. Compared to state-of the art processes where blowing agent is injected just before the die, inside of the polymer, the new feeding system could save valuable processing time and increase the overall throughput of the machine. Another application of the new feeding system could be reactive extrusion systems. Normal atmosphere contains about 5 % oxygen which can react with products inside the extruder. Nitrogen is often used for inert pressure atmospheres to carry out chemical reactions inside the extruder. It keeps oxygen in the air from interacting with the reactants and hinders side-reactions. The two very different atmospheres must be separated during the process. With this new feeding system, nitrogen or other gases could be applied to high pressures, supporting different reactive extrusion techniques. The developed equipment is easy to use and only requires a single motor to control. It also can be integrated into the control unit of the extruder for synchronization of the feeding mechanism. In summary, the new feeding system enables gas pressure inside a single- or twin-screw extruder while maintaining continuous granulate feeding.

About the Presenter

In 2016, I started as a student in plastics engineering at Technical University of Rosenheim. In my practical semester, I conducted an internship at the New Zealand based research institute Scion in 2019, and gained knowledge in reactive extrusion technology during the time. After that, I was involved in the development of pressurized reactive extrusion experiments and similar research topics. After my Bachelor of Engineering, I entered the master program "Applied research and development" at the Technical University of Rosenheim and finished the program with a Master of Science in 2021. Currently, I am pursuing my PhD in processing of wooden particles inside a twin-screw extruder at the Technical University of Berlin.

Abstract

Blister packs is one of the most important presentations in the pharmaceutical industry. As we all know, the brand owners and the global market are being pushed by the sustainability trends and regulations to look for alternatives towards recyclability. Typical structures of blister packs contain not friendly materials like PVC, PVDC OR PCTFE. This conference will present some test of structures using EVOH and COC creating a blister packaging with high barrier and excellent optical properties that also are design for mechanical recycling.

About the Presenter

Edgard Chow is the Director of Technical Service and Development for Kuraray. He has a Mechanical Engineering degree from the University of Houston and has 28 years of work experience in the polymer industry in various technical and leadership roles.

Over the last 20 years with Kuraray, Edgard has helped grow the core packaging business of EVAL ethylene vinyl alcohol copolymers in the Americas. More recently, he has been instrumental in developing new applications and commercializing the use of EVOH in new market spaces including Building & Construction Membranes, Waste Management Geosynthetics, and Agricultural Films.

Abstract

Short fiber reinforced thermoplastic parts subjected to mechanical and cyclic loading during a long period of time eventually fail. To prevent premature failure in service, predictability is key when designing load bearing components. The lifetime depends obviously on the nature of the thermoplastic material but also on the amount of reinforcement, the type of reinforcement and the set-up of the injection process. All these ingredients make the fatigue modeling of short fiber reinforced plastic parts highly challenging. Dedicated solutions at several stages of the modeling workflow are thus required. The ingredients needed are (a) an accurate material model for any orientation tensors and any loadings, (b) a reverse engineering procedure allowing to identify the model parameters from a reduced set of experimental data in order to reproduce the measured lifetime at specimen level, (c) efficient structural and fatigue solvers enabling to predict life-time for various type of loading conditions (constant amplitude, random signal, frequency/time domain loadings, and (d) an overall methodology able to account for stress gradients so to deliver accurate predictions for any part geometry and mesh. In this paper, an ICME (Integrated Computational Material Engineering) solution is presented, leading to accurate predictions of the fatigue life of short fiber reinforced parts for any type of experimental signal. The framework combines engineering tools that enable design engineers to predict fatigue life of engineering plastics applications, including material anisotropy and nonlinear behavior. This paper highlights the key features of the framework and demonstrates its ability to predict the response of a representative demonstration part.

About the Presenter

Dustin Souza is graduated with a Bachelor of Science in Aeronautical and Astronautical Engineering, with a major area of concenration in structures and a minor area of concentration in aerodynamics, from Purdue University. During his Masters degree, he worked extensively with Dr. Byron Pipes, in a number of areas of composites (from manufacturing to simulation). Dustin Souza joined e-Xstream Engineering to work on Digimat and support customer in US in 2013. He is now Senior Application Engineer in the Materials team in Hexagon Design Engineer part of Hexagon Manufacturing intelligence He is continuing to work on the modelling of various type of composite and support the biggest actors in the US Automotive market in their activities with Digimat.

Abstract

In recent years, biodegradable and compostable polymers have increasingly gained attention as a solution to combat the global plastic waste crisis. Many biopolymers such as Polyhydroxyalkanoate (PHA) are being studied and used to modify other polymers for various applications. Farrel Continuous Mixer (FCM) and Twin-Screw Extruder (TSE) are two compounding technologies widely used to make rubber and plastic compounds. To produce the compound, FCM relies on the rotor design in the mixer while TSE relies on the screw design. Studies have showed that FCM significantly reduces the specific energy input (SEI) for fossil fuel-based polymer modifications. However, one main advantage of TSE is that we can feed the materials downstream which could result in low residence time for more heat sensitive materials. Here, we will present comparison of the SEI of FCM and TSE for biopolymers compounding with an emphasis on blends of PLA and PHA. We will look at the SEI of 100% home compostable compound of amorphous PHA (aPHA) and crystalline PHA (cPHA) and how each machine affects the molecular weight and other properties of the compounded products.

About the Presenter

Yokly Lee received his BS/MS in Chemical Engineering from University of Oklahoma – Norman Campus in May 2022. His master program focused on polymer synthesis and characterization. His thesis emphasized on the synthesis and characterization of new phosphate-based hydrogel for biomedical applications. He also worked on polymer processing including poly (vinyl alcohol) blend and poly (ethylene oxide) blend during his time at the University of Oklahoma. After graduation, he joined CJ Biomaterials in June 2022 as a Process Development and Manufacturing Engineer. He is responsible for toll compounding and developing new products with amorphous PHA biopolymers.

Abstract

3D printing (3DP) uses computer-aided design to build objects layer-wise or drop-wise. 3DP complements conventional subtractive manufacturing methods, where unwanted material is removed from a piece of feedstock material by cutting, drilling, or grinding. 3DP has been successfully used to create complex, topologically optimized parts that are otherwise extremely difficult or impossible to manufacture using conventional methods. 3DP is especially well-suited for distributed manufacturing, mass customization, reducing tooling costs, and minimizing material wastage. This presentation will highlight some of our recent 3DP research activities, spanning from printing polymer composites, sensors, and magnets to food and drug tablets, using a variety of techniques, such as fused deposition modeling, digital light processing, direct ink writing, and binder jetting. While the need for 3DP is motivated differently by the specific applications, the key to success is founded on understanding the underlying physics. We will also share the lessons learnt in scaling up 3DP and pursuing a rather ambitious concept of "autonomous 3D printing", leveraging latest imaging and machine learning methods.

About the Presenter

Dr. Anson Ma is an Associate Professor of Chemical Engineering and Polymer at the University of Connecticut (UConn). His research group focuses on understanding and advancing 3D printing technologies. Dr. Ma currently serves as the UConn Site Director of the National Science Foundation (NSF) SHAP3D Center for additive manufacturing and the United Technologies Corporation (UTC) Professor in Engineering Innovation. He has received several awards, including Distinguished Young Rheologist Award from TA Instruments, NSF CAREER award, Arthur B. Metzner Early Career award from the Society of Rheology, 3M Non-Tenured Faculty Award, Early Career Award from the American Association of University Professors (AAUP)-UConn Chapter, UConn Polymer Program Director's Award for Faculty Excellence, and U.S. Air Force Summer Faculty Fellowship.

Abstract

Combining its own technology in polymerization and polymer rheology, Kaneka North America provides the processing aid to enhance the melt strength of bioplastics like PLA. The poor melt strength of PLA causes drawdown and sagging in the melt process, leading to low productivity. The processing aid dramatically increased the melt strength of PLA at 1 % loading level. During the extrusion process, it reacts to PLA and creates a comb structure. But it didn't affect optical properties without forming gels. It was also designed to keep the melt viscosity low so that the processing rates can be high. It worked for PHA as well. The 1% addition doesn't impact on the certification of biodegradability. This technology could enable access to more cost-competitive and sustainable bioplastics with a broader application window. Blow molding of bottles, film blowing, fiber spinning, and foaming could be facilitated by the materials exhibiting the high melt strength.

About the Presenter

Shusuke Yoshihara is the R&D Manager of Kaneka North America, Modifiers Division. He is developing impact modifiers and processing aids for PVC, engineering plastics, recycled materials and bioplastics. He previously spent 12 years at Kaneka Japan developing thermal solutions materials and KaneAce MX, epoxy masterbatch products. He has PhD in Engineering from Tokyo Institute of Technology.

Abstract

Machine Learning (ML) methods offer a great opportunity to model the complex behavior of the injection molding process. They therefore have the potential to predict the impact of various process and material parameters on the resulting part quality. The dynamic behavior of the injection molding process and the associated effort to collect process data are still a major challenge for ML methods. In this work, a hybrid approach is proposed to reduce the amount of data required for injection molding by combining process data with further process knowledge such as material models, flow equations and high-fidelity numerical simulations. A Physics-Informed Neural Network (PINN) is being used to model the relationship between process settings and physical process parameters. With the help of PINN, the governing differential equations and material models of the injection molding process are integrated into a machine learning algorithm. High-fidelity injection molding simulation results are used to further train and validate the hybrid process model. This approach leads to a data efficient surrogate model of a high-fidelity injection molding simulation for its holding and cooling phase.

About the Presenter

07/2021 - Present: PhD Student at the Robert Bosch GmbH in the corporate research section in cooperation with the IKV - Institute for Plastics Processing, RWTH Aachen, Germany. My research focuses on the combination of data- and physics-based modeling techniques for online and offline applications (e.g., Monitoring and Optimization) of the injection molding process. 10/2018 - 03/2021: M. Sc. Mechanical Engineering at Karlruher Institut of Technology (KIT), Karlsruhe, Germany Majors: Automation and production engineering Master thesis: Shape optimization of a CFRP component by geometry analysis and evolutionary algorithm. Part Time: Research assistant at the wbk - Institut of Production Technology, KIT, Karlsruhe 10/2014 - 09/2018: B. Sc Mechanical Engineering at KIT, Karlsruhe, Germany Major: Product development and engineering design Bachelor thesis: Modeling of massless oscillation in biological tissue. 10/2016 - 09/2017: Completed an exchange program at Universitat Politécnica de Catalunya (UPC), Barcelona, Spain, during the bachelor studies. Research focus during exchange: Numerical methods for simulation. Bachelor thesis was written during exchange year and results were published: Muñoz, Jose & Dingle, Mónica & Wenzel, Manuel. (2018). Mechanical oscillations in biological tissues as a result of delayed rest-length changes. Physical Review E. 98. 10.1103/PhysRevE.98.052409.

Abstract

In order to achieve more sustainability in rotomolded parts, several options are currently investigated. In this presentation, three possibilities are presented with typical examples produced at the lab scale (still under investigation). The first option is to use recycled resins instead of virgin ones. In this case, the recycled/virgin ratio can be change over the whole range of concentration; i.e. 0 to 100% recycled content. The second option is to add biobased fillers such as lignocellulosic fibres to get "greener" materials. In this case, the origin (wood, plants, etc.) and the particle size (mesh) are highly important. Finally, there is the possibility to use biosourced resins as the matrix. In this case, there is limitations in terms of availability and suitability of the resins for rotomolding processing, but good parts can be achieved after some optimization of the processing conditions (temperature, time, speed, etc.). Nevertheless, there is also the possibility to combine these options for specific applications (automotive, building, construction, outdoor, etc.). To get a clearer picture of the situation, typical examples will be presented and discussed in terms of physical and mechanical properties. Comparisons with petroleum-based resins is also included to determine the most interesting candidates for future developments.

About the Presenter

Denis Rodrigue obtained a B.Sc. (1991) and a Ph.D. (1996) in chemical engineering from Université de Sherbrooke (Sherbrooke, Canada) with a specialization in non-Newtonian fluid mechanics. In 1996 he moved to Université Laval (Quebec City, Canada) where he is now full professor. Since then, he has been an invited professor at the University of Guadalajara (Mexico), the Technical Institute of Karlsruhe (Germany), the University of Castilla-La Mancha (Spain), the University of Arts and Sciences of Hunan (China), the Technical University of Lodz (Poland) and Polytech Tours (France). His main research areas are in the characterization and the modelling of the morphological / mechanical / thermal / rheological properties of polymer foams and composites based on thermoplastics and elastomers. His main focus is related to polymer recycling and rheology.

Abstract

During the production of injection moulded components made of semi-crystalline thermoplastics, the material is locally exposed to different thermal conditions and thermal histories. While in the injection phase the surface layer material that gets in direct contact with the cold mould wall solidifies at cooling rates of up to 700 K/s, the core layer material solidifies at cooling rates of ~1 K/s, especially for thick-walled components. The significant differences of the solidification conditions lead to varying formations of the microstructure and the crystallisation degree across the thickness. Since the thermal conductivity depends on the crystallisation degree, a non-uniform thermal conductivity can be found through the thickness of the material. However, current injection moulding simulations do not take into account the decrease of the crystallisation degree towards the component edges by adjusting thermal conductivity depending on the local thermal history. To characterise the thermal conductivity in experimental tests, differential scanning calorimetry (DSC) analyses can be performed. However, DSC is typically limited to a maximum cooling rate of 0.5 K/s and thus cannot replicate the relevant crystallisation conditions for injection moulding. In contrast the Flash-DSC 2+, Mettler-Toledo, Ohio allows cooling rates up to 5000 K/s and thus covers the full range of injection moulding occurring cooling rates. The presented work will demonstrate a new methodology for the thermal conductivity characterisation using the Flash-DSC 2+. This approach enables the direct measurement of thermal conductivity as a function of the crystallisation degree and provides a more detailed description of the thermal boundary conditions in injection moulding processes and simulations. Initial experimental results show that a stacked test sample consisting of a polymer and a metal with a known and discrete melting point is suitable for measuring the thermal conductivity using the Flash-DSC 2+, analogous to the procedure using a conventional DSC. This methodology is verified in experimental tests with annealed polymer samples of isotactic polypropylene of the type PP505P, Sabic, Saudi-Arabia with a crystallisation degree of about 49 %. Thereby, it was demonstrated that the thermal conductivity is independent of the applied heating rate, which corresponds to the expectation. This allows the stacked test sample to solidify from the melt at any cooling rates and the measurement of thermal conductivity during subsequent re-heating at a high heating rates, which are characterised by a low noise to signal ratio. Since the solidification effects of the metal and the polymer can overlap especially at high cooling rates and a measurement of the crystallisation degree by Flash-DSC 2+ at very low cooling rates cannot be evaluated due to a high noise to signal ratio, the crystallisation degree depending on the cooling rate is empirically modelled by an additional measurement. Thus, for the first time, a measurement of the thermal conductivity as a function of cooling rate, respectively degree of crystallisation for the material is demonstrated here. This enables a more precise description of the thermal conditions within injection moulding simulations.

About the Presenter

Jonathan Alms, M.Sc. RWTH. Education/Study - Jonathan Alms studied physics at the RWTH Aachen University, Germany, specializing in condensed matter physics (Master). He wrote his master's thesis at the RWTH Aachen University, Institute for Plastics Processing (IKV) in Industry and Craft in the field of the application of artificial intelligence for quality assurance of polyurethane foams. Career path (2019 - present) - Since March 2019, he is working as a research assistant at the RWTH Aachen University, Institute for Plastics Processing (IKV) in Industry and Craft. He is employed in the Department of Structure Calculation and Materials Technology and leads the workgroup Materials Engineering, Digital Image Processing and Industry 4.0. Current research focus Development of a multiscale simulation for precise prediction of warpage of injection moulded parts.

Abstract

Many highly porous materials with pore volumes greater than 90% are attractive due to their high specific surface area and tunable surface energy. These materials cannot be easily adopted in advanced applications due to their poor mechanical strength and low handling stress. The advent of 3D-printing methods comes handy in such cases. The porous materials can be 3D-printed directly as metamaterials that offer much higher elongation and compliance in response to extensional stress than the parent porous materials themselves. The porous materials can also be made an integral part of 3D-printed, load bearing scaffolds to take advantage of their multi-functional attributes in thermal insulation, liquid-liquid separation, and nanoparticle removal from air with performance close to those of HEPA filters. This talk will illustrate three such examples. In one example, polyurethane aerogel metamaterials show substantially high elongation due to strategic arrangements of the highly porous limbs. In the second example, high porosity polyimide domains are grown inside or on surfaces of solid polymer scaffolds to produce excellent thermal insulation or efficient removal of noxious dye molecules from aqueous streams. In last example, variable surface energy strands of syndiotactic polystyrene or polyimide are used in removing water droplets from a hydrocarbon oil. Some generalizations will be made that other researchers can use and expand the concepts presented in this talk to an array of materials systems.

About the Presenter

Professor Sadhan C. Jana is currently the B.F. Goodrich Endowed Chair and Professor of School of Polymer Science and Polymer Engineering and Associate Dean for Research and Graduate Studies of College of Engineering and Polymer Science at The University of Akron. He is a chemical engineer by training with a Ph.D. degree from Northwestern University. Dr. Jana received National Science Foundation Faculty Early CAREER Award, Society of Plastics Engineers (SPE) Fred E. Schwab Award for outstanding achievements in education, George Stafford Whitby Award for distinguished research and education from the American Chemical Society Rubber Division, SR Palit Memorial Lectureship award from Society of Polymer Science India, Kamath Memorial Lectureship award from the Indian Institute of Chemical Engineers, and Honorary Professorship from National University of Colombia, Bogota. He is a Fellow and Honored Service Member of SPE and a Fellow of The Royal Society of Chemistry, UK. He is currently the Editor-in-Chief of Polymer Engineering & Science Journal and Executive Editor of all SPE journals - Polymer Engineering & Science, Polymer Composites, Journal of Vinyl and Additive Technology, and SPE Polymers journals.

Abstract

PHAs or polyhydroxyalkanoates are recognized for their unique ability to biodegrade in many natural environments including marine, home compost and industrial compost sites. As a result, PHAs are used in many applications where end of life is a critical value proposition. We have previously highlighted the value proposition of blending an amorphous grade of PHA (PHACT A1000P) from CJ Biomaterials in various compostable product formulations including those based on PLA, PBS, PBAT and starch. In this presentation, we will address new opportunities for A1000P in the non-compostable space. Specifically, we will highlight applications where incorporating A1000P into the formulation brings benefits that include biobased carbon content, flexibility and toughness. Examples will include enhancing the performance of products based on Acetal polymers, Nylon-11 and Nylon-12 and EVA.

About the Presenter

Raj Krishnaswamy is currently the Vice-President of Polymers R&D at CJ Biomaterials (Industrial Biotechnology Division). He has 20+ years of polymers R&D experience at Chevron Phillips Chemical, Metabolix and Braskem prior to his current stint at CJ. Raj is a co-inventor on 50+ patents and a co-author on 40+ publications. He is a Fellow of the Society of Plastics Engineering (SPE), has also been recognized with the Research/Technology lifetime achievement award by the SPE and is an alumnus of the NAE Frontiers of Engineering. Raj also serves on the advisory boards of the Macromolecules Innovation Institute at Virginia Tech and the Chemical Engineering Department at the University of Kentucky.

Abstract

Interconnectivity options for injection molding machines, e.g., communication interfaces such as OPC-UA, allow machine and process variables to be recorded in high resolution. This data can be used to improve quality monitoring, which may contribute to cost reductions by minimizing production waste or increasing the use of recycled material. Currently, for example, only small amounts of production waste can be recycled back into the process because the component quality otherwise shows a high fluctuation due to changes in material properties. Automated quality control and adjustment of the process parameters can counteract these fluctuations and thus enable a higher proportion of recyclate to be used in production. In addition to the resulting savings, production costs can also be reduced by increasing product quality. This reduces the rate of production waste, for example, which contributes significantly to more economical and sustainable production. For these reasons, control of the quality properties of the manufactured components has been sought in injection molding for decades. However, the control of component properties requires their direct measurement within the production cycle, which is often not possible, very cost-intensive and/or cannot be carried out non-destructively. For this reason, it is common practice to control machine or process variables that correlate with component quality instead. However, the injection molding process is affected by numerous non-measurable disturbance variables which influence the transmission behavior of the machine, so that identical process parameters do not result in identical process variable curves and finally do not result in identical component quality. Thus, it is necessary to develop an assistance system based on a digital twin of the injection molding process, which supports the machine operator in setting the process parameters of the injection molding machine in such a way that a desired part quality results. As part of this study, a digital twin of a real injection molding process was developed on an Arburg injection molding machine (Allrounder 470S, ARBURG GmbH + Co KG, Lossburg, Germany). Essentially, the work involved the following steps: Setting up a quality measuring cell that records the relevant component qualities, developing a software module that records all relevant machine and process variables cycle-related as single values and trajectories, and modeling the digital twin that predicts the resulting component quality on the basis of the recorded variables. A laboratory scale and a digital measuring projector were used to determine the quality characteristics, so that the component weight and dimensional accuracies, e.g., diameter and width, were measured from the injection-molded tamper-evident closure after each cycle and assigned to the recorded machine and process variables of the corresponding cycle. The machine and process variables were retrieved via the OPC-UA interface of the injection molding machine. Process variable trajectories, such as cavity pressure, cavity temperature, injection pressure and injection speed curves, must be recorded in high resolution for reliable modeling due to the short duration of the injection process. All machine and process variables as well as the quality variables measured after the cycle are stored in a database file assigned to the cycle number. With the data retrieved from a design of experiment divided into training and test data, different static and dynamic model structures were tested according to their best fit rates (BFR). The different modelling approaches can be divided into three categories: 1)Setpoint model: The machine setpoints are mapped directly to the resulting part quality. A Polynomial Regression (PR) model and a Multilayer Perceptron (MLP) were employed. 2)Measurement-features model: The final part quality is predicted from the machine setpoints and from features extracted from process measurements based on expert knowledge, i.e., maximum cavity pressure and temperature, or temperature in the cavity at the beginning of the injection phase. As for the setpoint models a PR model and a MLP were employed. 3)Internal dynamics model: A modern type of Recurrent Neural Networks (RNN), a Gated Recurrent Unit (GRU) is used to predict batch-end product quality from process value trajectories. The internal state of the GRU is mapped to the output via a feedforward Neural Network with a nonlinear hidden layer and a linear output layer. Since the injection molding process is a time-varying process switching between different machine internal controllers, the model was also divided into the three major phases of the processing cycle (injection, packing, cooling). Since the third phase maps the internal state to the output, it is additionally equipped with an MLP. If the BFR of the individual models are compared, it can be seen that even the simple setpoint models can predict the component quality very well. The 10th degree PR model, for example, achieves a BFR of 90%. The fact that the models which predict the part quality only on the basis of the parameters set on the machine achieve very good results in this test series could be due, among other things, to the fact that all disturbance variables affecting the process were excluded or kept constant as far as possible during the test. For the models that take into account features calculated from the trajectories in addition to the setpoints, the MLP with ten neurons in the hidden layer achieved the highest BFR of 93%. Compared to these two static model approaches, the dynamic GRU achieves only marginally better BFR. On the one hand, it is astonishing that these models can predict the part quality so well based on the raw data without any prior knowledge from experts; on the other hand, the high computational effort for the formation of a digital twin, especially for short cycle times, cannot be justified. For the actual digital twin, static model approaches were therefore used whose computing times are significantly shorter. While the pre-trained twin receives the new machine and process data after each cycle in live operation of the injection molding machine and predicts the component quality from this, it then compares this prediction with the measured quality variables and re-trains itself based on the error. In this way, it learns to describe the process even better over time. Using backpropagation, the digital twin can also calculate the optimum machine settings for a desired target variable of the quality characteristics.

About the Presenter

Marco Klute studied mechanical engineering with specialization in plastics engineering at the University of Kassel/ Germany. His master thesis focused on two-component injection molding of polyamide and liquid silicone rubber (LSR) using different surface treatments. Since 2017 he has been working as a research fellow at the Institute for Material Engineering - Polymer Engineering at the University of Kassel, in the field of natural based composites as well as simulation and machine learning. He is currently working on two-component injection molding of bio-based polymers regarding material development and analytics of adhesion characteristics as well as the digitalization of injection molding processes using digital twins (supervisor Prof. Dr.-Ing. Heim).

Abstract

In line with Europe's green deal, a new edition of the European action plan for a transition to a circular economy has been published in 2020. Amongst others, plastics have great potentials to achieve a high level of product circularity. In recent years, the plastics recycling industry has gained a great momentum to be one of the drivers towards a sustainable circular economy. However, there is still an abundance of challenges that need to be addressed and overcome in this sector. Therefore, a great focus in the new action plan is dedicated to plastics and plastic packaging products. Consequently, a set of mandatory or voluntary product requirements and regulations were reinforced or introduced as part of a new framework for eco-design and sustainable products. Furthermore, this legislative initiative also aims to enhance the traceability and the accessibility to product information through the implementation of certain digitalization tools, such as digital product passports (DPP). The main objective of this research is to provide a practical implementation of DPP of a pilot product made of recycled post-consumer plastic waste. It also aims to track the possible changes in the material property profile of a defined waste stream due to processing throughout the whole recycling process. High density polyethylene (PE-HD) bottle caps were selected as the targeted input waste stream. On the other end of the process, a frisbee (i.e., flying disc) was selected as the pilot product. Two collection methods were employed in this case study, namely informal and formal. The first fraction of bottle caps was collected by pupils and students (informal) over a period of two months in Upper Austria region with focus on PE-HD bottle caps. Whereas the other fraction was collected via the conventional methods (formal) and pre-sorted (1st sorting) to remove metal contaminants at the waste collection centers in Upper Austria. At the pilot plant, each fraction was hand-sorted (2nd sorting) individually to ensure a high purity of input materials. Afterwards, materials were shredded by an industrial shredder and then re-granulated using an industrial recycling extruder equipped with filtration and degassing systems. Thereafter, the resulting recyclates were injection molded into the finished frisbee. To characterize the material property profile of the different material states, several measurements including melt flow rate (MFR), differential scanning calorimetry (DSC), and mechanical tests were carried out. It was found that the informal collection led to a higher material purity as the other fraction had a more prominent melting peak of polypropylene (PP), which led to a slightly higher MFR value of this input fraction. However, no significant changes in the MFR values of the other materials were observed. In terms of the mechanical properties, the tensile stiffness and strength increased after processing. In contrast, the notched Charpy impact strength of the recyclates seemed to be slightly lower than that of both input streams.

About the Presenter

Currently, I am working as a research engineer at Competence Center CHASE (since Feb. 2020) and, simultaneously I am a PhD candidate at Johannes Kepler University Linz, Austria. I am responsible for the characterization and testing of the recycling materials and the development of standardized quality control methods. Moreover, my responsibilities also expand to research project coordination and working together with my colleagues on the optimization of the recycling process through implementation of digitalization tools. Previously, I worked for two years at two different international companies in Upper Austria as a Quality Engineer and as a Product Engineer in the polymer and chemical sectors before I decided to shift back to research and pursue my doctorate degree in polymer technologies with focus on plastics recycling. By education, my background is a combination of industrial engineering with plastics engineering. I obtained a 5-year Bachelor of Mechanical Engineering (specialization of industrial engineering) from University of Aleppo, Syria. Afterwards, I acquired a master's degree in management in polymer technologies from Johannes Kepler University, Linz, Austria.

Abstract

Processing of thermoplastics during injection molding and blow molding usually includes rapid cooling with rates up to 103 K/s and solidification at high supercooling. Fast scanning calorimetry (FSC), an advanced calorimetry, is able to cover high processing rates and wide temperature windows by just using a few nanograms of the sample. With the advent of FSC, the crystallization fingerprint of many thermoplastics has been revealed. In this work, we expand the existing capability of FSC by coupling it with other techniques, including micro-IR spectroscopy (Micro-IR), atomic force microscopy (AFM), polarized optical microscopy (POM), and X-ray computed tomography (XCT). Polymorphism and morphology transition associated with processing conditions will be discussed in polyamide 66, polyamide 6, poly (ether ether) ketone and its composites. A more accurate simulation of plastic solidification can be achieved using fast scanning calorimetry and related technology.

About the Presenter

Xiaoshi Zhang is a Researcher at the department of plastics engineering technology at Penn State Behrend. Xiaoshi is a plastic professional with more than 10 years of research experience in thermoplastics. Xiaoshi specializes in thermoplastics crystallization and polymer characterization. Xiaoshi received his Ph.D. in chemical engineering from Florida State University. His current research is focused on understanding the crystallization of thermoplastics under processing relevant conditions, such as high cooling, low temperature, and, high shearing, etc. Xiaoshi has publications in peer-reviewed journals including Macromolecules, polymer engineering & science, etc, and gives talks at ACS, APS, NATAS national meetings.

Abstract

Processing thermoplastic high-performance polymers in general is challenging. 3D printing such materials is near impossible. We are exploring precursors (reactive oligomers) to high- performance polymers, resins with more facile processing characteristics. REAPER (REACTIVE HIGH-PERFORMANCE RESINS) is a patented technology platform that specializes in high- performance polymers for additive manufacturing. Our first two target materials, amorphous PAI and PEI, were both previously unprintable using SLS (Selective Laser Sintering) and FDM (Fused Deposition Modeling). By using the reactive intermediates xPAI and xPEI we generate readily printable materials with glass transition temperatures of 300C (572F) and 200C (392F) respectively. These materials are designed for commercial scale-up and are printer agnostic and THE REAPER reactive oligomers' molecular weight and viscosity increases on heating above the flow point where the oligomers begin to chain extend and to cross-link via thermally activated end- group chemistry. Our patented technology exploits this chemistry during the printing process to create a robust weld line between successive FDM or SLS layers via the formation of covalent chemical bonds. I will describe the motivation and chemistry underlying our novel approach to 3D printing high performance polymers.

About the Presenter

Samulski is emeritus Cary Boshamer Professor of Chemistry, at the University of North Carolina, Chapel Hill, where he he served as Chair of the Department of Chemistry . He is also co-founder of Liquidia Technologies, a Research Triangle start-up company based on collaborative work with UNC colleague Joe DeSimone; Liquidia went public in 2018. In 2008, he founded Allotropica Technologies, a start-up exploring new composites. In 2013, with DeSimone and Alex Ermoshkin he founded Carbon a 3D printing company located in Redwood City, CA; they have raised over $650 million binging 3D printing options to a variety of sectors. In September 2020, with his former PhD student Theo Dingemans, he's launched another company BlueSky Polymers LLC focused on high-performance polymers.

Abstract

The current shift from solely depending on petroleum sources to seeking renewable alternatives is attributable to their fast depletion, erratic prices, and the need to reduce our carbon footprint. For instance, the polyurethane industry currently calls for renewable (and less toxic) polyols and isocyanates for their synthesis over the traditional petroleum-based ones. To tackle these issues, we have investigated the role of vegetable/fruit oils in the preparation of polyurethane foams. Different approaches such as thiol-ene click chemistry and epoxidation, followed by ring opening, were used to convert these oils into polyols. The effect of the synthesis process on the properties of polyurethanes was studied. One of the major issues in polyurethanes is their high flammability. To reduce the flammability of polyurethane foams, different types of flame-retardants (additive and reactive) were investigated during the foaming process. The effect of flame-retardants on the physicomechanical and flammability of the foams was investigated in detail. Most of the foams displayed density in the range of 30-55 kg/m3 which is suitable for many applications. The compressive strengths of these foams were higher than 160 kN/m2. Except for some high concentrations of flame retardants, most of the foams showed closed cells greater than 90%. It was found that the burning time of the foams reduced significantly after the addition of flame retardants. For example, foam prepared using sunflower oil-based polyols showed a reduction in burning time from 79 seconds to 2 seconds after the addition of 13.61 wt.% of dimethyl methyl phosphonate. The effect of various flame-retardants and the role of bio-based polyols on the properties of polyurethane foams will be discussed. Our research suggests that a variety of bio-based materials can be used for the polyurethane industries with a reduced impact on the environment.

About the Presenter

Dr. Ram Gupta is an Associate Professor at Pittsburg State University. Before joining Pittsburg State University, he worked as an Assistant Research Professor at Missouri State University, Springfield, MO then as a Senior Research Scientist at North Carolina A&T State University, Greensboro, NC. Dr. Gupta’s research focuses on green energy production and storage using conducting polymers and composites, electrocatalysts, fuel cells, supercapacitors, batteries, nanomaterials, optoelectronics and photovoltaics devices, organic-inorganic hetero-junctions for sensors, nanomagnetism, bio-based polymers, bio-compatible nanofibers for tissue regeneration, scaffold and antibacterial applications, bio-degradable metallic implants. Dr. Gupta published over 250 peer-reviewed articles, made over 320 national/international/ regional presentations, chaired many sessions at national/international meetings, wrote several book chapters (55+), working as Editor for many books (20+) for American Chemical Society, CRC, and Elsevier publishers, and received over two million dollars for research and educational activities from external agencies. He is serving as Associate Editor, Guest editor, and editorial board member for various journals.

Abstract

Accompanying the era of digitalization into business leads to a new manufacturing concept called "Smart Factory". Smart Factories promise more efficient production processes, manifesting in integrated autonomous asset configuration and data-based decision-support in the operator's daily business. Therefore, mapping the production assets into the virtual world by establishing their interconnection and to enterprise software systems is essential. Although the origin of Smart Factories lies in 2011, it can be identified that integrated Smart Factories are rarely implemented and often comprise one encapsulated, specific use case. One main reason is a lack of standard semantics that serves as a basis for asset communication and providing decision-support. This contribution presents the foundations for enabling an integrated smart factory within the injection molding domain and demonstrates a real use case that presents the benefits of a smart injection molding factory. As a basis, the reference architecture model industry 4.0 (RAMI 4.0) with respect to the characteristics of an injection molding factory is analyzed. The RAMI 4.0 consists of three dimensions: business layers, life cycle and value stream, and enterprise hierarchy levels, and it allows concrete derivations of technologies, their requirements, and their interactions. Two of these technologies are Digital Twins and Digital Shadows. Digital Twins represents the asset virtually. The Digital Twin provides all relevant properties, ideally in a standardized manner, and pictures its master data (e.g., id, vendor, year of manufacture) as also its transaction data, e.g., current temperature or the number of cycles, into the virtual world. Another core technology is Digital Shadows. The Digital Shadow uses the exact dataset and suitable models for solving a specific task, e.g., calculating an optimal shopfloor configuration, and acts as decision-support for deciders. This contribution gives insights into building Digital Twins and Digital Shadows using the RAMI 4.0 concerning the characteristics of an injection molding factory. Furthermore, it will demonstrate how Digital Twins and Digital Shadows can interact autonomously by introducing semantics and dictionaries. Hence, a draft of a standardized dictionary for the injection molding domain, enriched with metadata that describes the dictionary terms semantically, is provided. This contribution focuses on the shopfloor level, i.e., production planning and control. Thus, a real case in scheduling production orders within an injection molding factory will be applied. Inside this use case, the Digital Shadow retrieves suitable optimization models for providing decision-support under consideration of trade-offs in different optimization objectives and the current condition of the injection molding assets using the corresponding Digital Twin. It can be shown that the Digital Shadow autonomously provide decision-support for production planners so they can initiate an optimal schedule.

About the Presenter

Patrick Sapel, M.Sc. - Education/Study: Patrick Sapel studied part-time business administration and engineering at the University of Applied Sciences in Hagen, Germany (Bachelor). During his part-time study, he worked in a medium-sized company in the field of master data and manufacturing preparation. In his master's program at the University Duisburg-Essen, he studied Logistics Engineering. - Career path (2019 - present): Since May 2019, he is working as a research assistant at the Institute for Plastics Processing at RWTH Aachen University. He is employed in the Department of Injection Molding and leads the workgroup Production Planning and Automation. - Current research focus: Foundation of Digital Shadows within the Cluster of Excellence "Internet of Production" at RWTH Aachen University.

Abstract

Various approaches for incorporating post-consumer recycle (PCR) into polyethylene based rigid packaging application have been explored using a model system comprised of multiple virgin resin components. These formulations were prepared using both a blending approach as well as a one-pellet solution approach. In the former approach, materials are dry blended and fed into an injection molding machine and the later approach involves pre-compounding the materials followed by injection molding. The selection of components included in each model system formulation was influenced by the desire to vary the relative melt index of the components to study the influence of polydispersity. Performance property comparison of the various model systems included quantification of tensile, flexural, part density, melt index, and shrinkage properties of the fabricated parts as well as quantification of processability. Formulations containing real-world PCR were also included in the study to probe the influence of contaminants and degraded polyethylene on performance properties.

About the Presenter

Dr. Mubashir Q. Ansari is currently an Associate Research Scientist at The Dow Chemical Company, where he leads an injection molding facility, partnering with various Dow businesses selling products into rigid packaging applications. His research interests include capability development, product development, and supporting automation and data integration developments that advance digitalization (i.e., "big data") of polymer processing workflows. His interests span virgin resin development for monomaterial packaging, sustainable additives, post-consumer recycled resins, and thermoplastic formulation development for electric vehicles. He received his PhD in Chemical Engineering from Virginia Tech, where he worked in Prof. Donald Baird's research group. While there, his research was focused on generating patented composite filaments for 3D Printing Applications. Dr. Ansari received his undergraduate degree in Chemical Engineering from IIT (BHU) Varanasi, after which he worked as a Process Engineer in a petroleum refinery. Dr. Ansari's work at Dow has included technical developments that have aided in the commercialization of five products. He is proud to be part of the team that worked on Dow's first post-consumer recycled resin product, AGILITYTM. Dr. Ansari has one granted patent, one patent application, and 11 peer reviewed papers (conference and journal) to his credit. He is a member of ad-hoc committee on Society of Rheology's future conferences and board member of Society of Plastics Engineers (SPE) Thermoplastic Elastomers' Special Interest Group. He was recently recognized as 2022 Rising Star by PlasticsNews, a recognition given to under 35-year-old leaders in the plastics industry or those who are on track to become one.

Abstract

Though (EU) No 2020/1245 — the so-called, "15th Amendment" to (EU) No 10/2011 (The Regulation) — officially entered into force in September of 2020, it was written to allow two years for business operators to exhaust their stocks of materials which had already been declared to be in compliance with The Regulation prior to the 15th Amendment. Between this grace period and the official date of publication, the 15th Amendment shall be considered to be in full effect as of September 2nd, 2022. Included in an array of adjustments to declaring compliance of products expected to come into contact with food under Annex IV of The Regulation is the obligation of business operators who produce intermediate substances to provide adequate information about the migration of respective impurities and degradants for which genotoxicity has not otherwise been ruled out. Consequently; impurities and degradants of commonly used plastic additives which currently have ambiguous toxicological profiles must now be shown not to migrate to food or food simulant from the intermediate material(s) in which they exist at a rate of 0.00015 mg/kg (0.15 parts-per-billion). In light of this obligation, research has been conducted into the presence, detection of, and reporting on impurities and degradants of the prevalent plastic additive Anthranilamide (CAS No. 88-68-6). The degradants of Anthranilamide are representative of compounds which exhibit unknown toxicological status and are the epitome of the rationale for the inclusion of this concept in Annex IV of the 15th Amendment. The work presented in this paper sought to explore the challenges in adhering to the amended requirements in Annex IV of The Regulation insofar as how low the threshold of migration is set as well as options to consider for business operators producing intermediate compounds in the EU and the US who will both likely see increased demand for such declaration of compliance. As a subject, Anthranilamide is merely representative of all plastic additives that can give rise to degradants or which exhibit impurities that have unknown toxicological status and the ideas presented here are meant to be used generically in how best to navigate a new era of food contact plastics compliance requirements.

About the Presenter

CURRENT ROLE WITHIN THE PLASTICS INDUSTRY - Regulatory/compliance specialist for colorants, adjuvants and impurities used or found in compounding with emphasis on food-contact materials - Food contact compliance testing consultant, technician and impurities researcher.

BRIEF PROFESSIONAL BACKGROUND - NIAS quantification method development manager - Extensive experience developing and conducting migration fastness studies - REACH sameness testing and dossier preparation manager - Liquid and ion chromatography specialist - Master of Science (MS) in Chemistry with focus on dyes and small organic molecules

Abstract

Hydrophobically modified hydrogels based on statistical copolymers of a water soluble monomer and a fluoroacrylate exhibit extraordinary fracture toughnesss, ~ 10^4 J/m^2. The origin of the toughness is a nanostructuredd morphology consisting of hydrophobic nanodomains dispersed in a water-swollen polymer continous phase. The hydrophobic associations within the nanodomains serve as the fundamental crosslink for the network, and the reversible nature of these physical crosslinks provides a mechanism for energy dissipation by rearrangement of the hdyrophobic groups when under stress. The reversible crosslinks also allow the hydrogels to be extruded in the dry or wet state or injected as in situ forming hydrogels for biomedical applications such as tissue engineering and regenerative medicine. The very small distances (< 10 nm) between nanodomains affects the mobility of water in these hydrogels, and even at relatively high water contents (> 50%), the hydrogels suppress freezing of the water. For nanodomain separations ~ 2 nm, a confinement effect prevents freezing of water to temperatures as low as 128K, which suggests that these hydrogels may have useful applications as antifreeze materials for biomedical, agriculture or food applications. Hybrid gels with a covalent network in addition to the physical network exhibit shape memory effects.

About the Presenter

Robert Weiss retired from the University of Akron in 2016, where he was the Hezzleton E. Simmons Prof. of Polymer Eng. and served as the Chair of the Dept. of Polymer Eng. and Associate Dean for Research in the College of Polymer Science and Polymer Engineering. Prior to joining the University of Akron in 2009, he was a Board of Trustees Distinguished Professor and the United Technologies Corp. Prof. of Advanced Materials and Processing at the University of Connecticut where he served 10 years as Director of the Polymer Science Program and 6 years as the Associate Director of the Institute of Materials Science. Bob retired from UConn in 2009 and is currently Distinguished Emeritus there. He received a B.S. in chemical engineering from Northwestern Univ. in 1972 and a PhD in chemical engineering from the Univ. of Massachusetts in 1976. He spent 5 years at Exxon Chemical and the Corporate Research Laboratories of Exxon Research and Eng. Co. before joining the Chem. Eng. Dept. at UConn in 1981. He is a Fellow of the American Physical Society, the American Chemical Society, the Society of Plastics Engineers (SPE) and the North American Thermal Analysis Society He was a Fulbright Scholar at Imperial College (London) in 1987-88 and was elected to the Connecticut Academy of Science and Engineering in 1990. He received the SPE Education Award in 2000, SPE Research Award in 2002, SPE Engineering and Technology Award in 2003 and the SPE International Award in 2008. He was awarded a doctor honoris causa from Brno University of Technology (Czech Republic) in 2012. Bob’s research interests include structure-property relationships of multiphase polymers, notably ionomers, block copolymers, liquid crystalline polymers, polymer blends, elastomers and gels. He has published 276 journal papers and 330 conference proceedings and has 26 U.S. patents. He served 25 years as associate editor and editor-in-chief of the journals Polymer Engineering and Science and Polymer Composites.

Abstract

Kraft lignin is a by-product of the pulp and paper industry in excess of 70 M tons a year. While limited applications exist for its commercial use, those related to plastic applications are very rare. Lignin's chemical complexity and limited compatibility with existing materials has largely stunted its adoption as a mainstream raw material for bioplastic production. In this presentation, unique avenues are presented for the use of lignin as a reactive precursor in the synthesis of polyurethanes and polyamides suitable for packaging applications. New polyurethane foams have been innovated without the use of isocyanates to replicate the low density and cushion characteristics of flexible packaging material. Typically used in rigid applications due to its multifunctional character, the use of lignin in flexible foams requires unique techniques to synchronize the gelling and foaming reaction responsible for the foam structure. The same chemical modification of lignin enables its incorporation in extended polyamide networks containing 100% biobased carbon. The incorporation of lignin maintains the thermoplastic character of the polyamide while greatly increasing the melt-strength to facilitate processing in modern equipment. The new lignin-polyamide polymer can be compression molded, punched, thermoformed, and glued as a representation of its utility in flexible packaging. These new polymer structures advance the outlook for lignin in the biorefinery concept where all of biomass needs to be valorized to compete with other lower cost chemicals and precursors.

About the Presenter

James Sternberg is a Senior Scientist at the Clemson Composites Center in Greenville, SC and a Research Assistant Professor in the Department of Automotive Engineering at Clemson University. James comes from a chemistry background having completed his B.S. and M.S. in chemistry before completing his PhD by studying biobased polymers under Professor Srikanth Pilla at Clemson. James's work focusses on redesigning polymer systems to be biobased and chemically recyclable. His projects have included recycling and/or redesigning polyurethane foams, nylons, composites, and 3D printing materials. He is currently the leader of the chemical recycling and upcycling group at the Clemson Composites Center.

Abstract

A Digital Twin (DT) can be defined as a digital representation of an actual physical system, where the data flow between the virtual and the real entity is fully integrated in both directions. In this work, a soft-sensor-based DT was developed for the real-time monitoring of the most important quality indexes in the manufacturing of plastic extruded tubes, i.e. the weight per unit length and the inner diameter. An extensive experimental campaign was conducted on a real tube extrusion line using three polyvinyl-chlorides (PVC) and different process conditions, and machine learning regression algorithms were trained and tested to create the models of the extruder and the extrusion die, on which the DT is based. The characterization of the considered material, whose properties were given as input to the digital models, was carried out according to a procedure based only on the data collected by the production line. The DT was tested for the startup of the production of a single-layer tube, and allowed to achieve the specified customer requirements (thickness and weight) in few minutes. The proposed solution thus proved to be a useful tool for reducing the setup time, thus increasing the efficiency of the process.

About the Presenter

PhD Student - Digital Manufacturing - Polymer Processing Group at Department of Industrial Engineering (UniPd). After I earned a MSc in Product Innovation Engineering (Mechanical Engineering curricula), I obtained the abilititation for the profession of Industrial Engineer. As a PhD student, my research activity is focused on the development of Digital Twins for polymer processing technologies as innovative solutions within the framework of the industrial digitalization

Abstract

The production of conventional cross-linked polymer networks and their composites, i.e., thermosets and thermoset composites, was estimated to consume more than 40 billion kg of polymer in 2020. Unfortunately, thermosets cannot be melt-reprocessed into moderate- to high-value products because permanent crosslinks prevent melt flow. Three of many examples include rubber tires, disposed at a rate of ~300 million annually in the U.S. alone, polyurethane (PU) foam, and cross-linked polyethylene, with major economic and sustainability losses resulting because the spent materials are commonly landfilled or burned for energy. Here, I will report on research demonstrating the ability to employ simple one-step or two-step reactions to produce networks and network composites with dynamic covalent crosslinks that are robust at use conditions but allow for melt-state reprocessing at elevated temperature. Unique to our research group, we have developed several approaches that allow for melt-state reprocessing of addition-type polymer networks and network composites, including those synthesized directly from monomers containing carbon-carbon double bonds, such as those used in coatings and flooring, and those synthesized from polymer or combined polymer and monomer with both containing carbon-carbon double bonds, like materials used in tires and in cross-linked polyethylene. All approaches allow for full crosslink density recovery after multiple reprocessing steps. We have also demonstrated for the first time the ability to make PU and PU-like networks, e.g., polyhydroxyurethane and polythiourethane networks, reprocessable with full recovery of crosslink density. An "Achilles' heel" has been identified regarding the application of dynamic covalent networks, i.e., such networks are subject to creep at elevated or sometimes even room temperature, which is often highly undesirable. We have addressed this limitation in two ways. In one case, we add a fraction of permanent crosslinks to dynamic covalent networks. In a second class of systems, we employ dynamic chemistry with a sufficiently high activation energy, allowing for reprocessability at high temperature but with the dynamic chemistry essentially fully arrested well above room temperature, e.g., 70-80 degrees C. Implications of these studies for making major gains in the sustainability of polymer networks and network composites will be discussed.

About the Presenter

John Torkelson is a Walter P. Murphy Professor in the Department of Chemical and Biological Engineering and the Department of Materials Science and Engineering at Northwestern University. John received his B.S. in Chemical Engineering from the University of Wisconsin-Madison and his Ph.D. in Chemical Engineering from the University of Minnesota. During his time as a faculty member at Northwestern, he served as Associate Dean for Graduate Studies and Research in the McCormick School of Engineering and Applied Science from 1997 to 2002. In 2003 - 2006, John was the Director of the Materials Research Center at Northwestern University, which receives its main funding from the NSF-MRSEC Program. He was the recipient of both Teacher of the Year and Advisor of the Year Awards from the Engineering School and the Northwestern Alumni Association Excellence in Teaching Award. For three years, he was also the Charles Deering McCormick Professor of Teaching Excellence. John has served as Chair of the Division of Polymer Physics of the American Physical Society (APS) and Chair of both Area 8A Polymers and the Materials Engineering and Science Division of AIChE. He has been recognized in research by the Polymer Physics Prize from the Journal of Polymer Science: Polymer Physics and the Charles M. Stine Award from the Materials Engineering and Science Division of AIChE, and he is a Fellow of the APS as well as AAAS.

Abstract

There are unique opportunities to develop coatings for non-urea fertilizers and provide desired performance such as enhanced controlled nutrient release and dust resistance. The key contributions from this work; provided advanced analytical solutions to evaluate fertilizer coating quality and developed quantitative QC tools for nutrient release and dust resistance. In conclusion, developed hydrophobic polyurethane fertilizer coating solutions that provides significant shelf stability and controlled nutrient release.

About the Presenter

Praveen Boopalachandran is currently a Research Scientist at the Dow Chemical Company. His expertise is in the area of optical spectroscopy and process analysis. Praveen serves as a R&D focal point for Dow polyurethane business to provide analytical solutions for new product development and existing product offerings. Praveen also serves as a global technology network leader for optical spectroscopy. Praveen is a certified Six Sigma Green Belt project leader. Other leadership roles include integration coach for new hires, interview team and technical mentor in Core R&D. Before joining Dow, he was a Postdoctoral research associate at the University of Minnesota, and he received his Ph.D. from Texas A&M University.

Abstract

The unique properties of polymer and plastic materials enable a broad array of applications. Some examples include food safety, medical sterility, renewable energy generation, and even building envelopes all require the functionality of polymers and plastics. As soon as the function is delivered, such as an empty water bottle, the continued persistence and durability transform the plastic from a benefit to a burden. Modern formulations often have a mismatch between the design life and the service life of plastic. The public has invested in separating the post-use durable plastic with the assumption that it would be recycled. Estimates of the recycled volume are less than 10%. This accumulated plastic waste has recently attracted new regulations and financial incentives to encourage new solutions to accumulating plastic waste. In this presentation, we will explore traditional pathways for post-use plastic including recycling, and conversion to fuel. We will explore a novel solution to the plastic waste problem, tunable plastic durability. This concept is to design traditional formulations that match the design life to the service life and have the material degrade post-use. The presentation will detail the use of UV photocatalytic degradation of post-use plastic.

About the Presenter

Dr. White is a senior managing scientist in the Polymer Science and Materials Chemistry Practice at Exponent, Inc., an engineering and scientific consulting firm. Exponent is a publicly traded company that employs over 900 full-time staff worldwide, including about 700 degreed professionals, more than 425 of whom hold doctorates in their field. One of Dr. White's core competencies is characterizing weather-related changes to polymers' chemical and physical properties and how those degradative changes may affect end-use performance. This expertise enables him to provide solutions to complex issues related to assessing recyclability. durability, failure, sustainability, and climate change effects on materials and assets exposed to weathering. He is skilled in developing and utilizing test methods and standards to analyze plastics, rubbers, textiles, metals, glass, and ceramic composite materials. Dr. White is experienced in offering technical guidance throughout all phases of product development, including formulation, scale-up, end-use testing, and field performance assessments. Dr. White was educated at the University of Maryland and holds a Master of Business Administration in addition to a Ph.D. in Polymer / Analytical Sciences from the University of Wisconsin and Bachelor of Science in Chemistry from Wabash College. Prior to joining Exponent, Dr. White worked at the National Institute of Standards and Technology (NIST) in the Engineering Laboratory, where his work focused on developing test methods related to quantifying the durability of polymer materials exposed to outdoor weathering. Dr. White served as a Lecturer teaching Project Management, Ethics, and Social Networking for the Robert H. Smith School of Business at the University of Maryland.

Abstract

This presentation provides an example of comparative Life Cycle Assessment for fossil-based and bio-based polymers that are non-compostable and compostable respectively. In this instance, fossil-based and non-compostable gloves made from polyethylene were compared with our commercial bio-based and compostable gloves utilizing ISO 14040:2006, ISO 14044:2006 and ISO 22526:2020 standards. As bio-based materials are created on a much shorter timescale than fossil-fuel reserves, some consider bio-based polymers to be a form of carbon sequestration. This means that bio-based polymers can be said to have a lower feedstock carbon emission burden than fossil-based alternatives. A major discrepancy, however, when comparing fossil-based and bio-based materials largely arises due to how biogenic carbon is accounted. This normally stems from how bio-based materials have their system boundaries drawn, where sequestration of CO2 is immediately tied to end-of-life emissions and taken as a net zero summation. This handling is the current methodology employed by the European Union Product Environmental Footprint (EU PEF) which states, "removals and emissions of biogenic carbon sources shall be kept separated in the resource use and emissions profile". We compare this mindset to that of ISO standards and give a representative understanding where fair comparisons are possible for fossil-based and bio-based plastics, and when fossil-based materials are preferentially benefited with this tactic. In doing so, this presentation will provide the audience with an understanding on the bias LCA methods have against bio-based materials when biogenic carbon is not properly accounted for and give specific criteria which allows for a fair comparison with their fossil-based counterparts.

About the Presenter

Dr. Anthony Keyes received his Ph.D. in the Fall of 2021 from the University of Houston in Polymer Chemistry for his work in block copolymer synthesis which bridged radical and insertion polymerization techniques. During that time, he served as Vice President for his local SPE Chapter where he received awards in the Flexible Packaging Division of SPE, UH Polymer Center of Excellence award, and was a recipient of the NSF-GRFP. He joined Natur-Tec® as their Polymer Formulation Engineer and currently works with compostable polyesters which find uses in blown film and injection molded applications.

Abstract

Regardless of the industrial sector, the identification of components, packaging and entire products is becoming increasingly important. In addition to production-related identification and registration of components, individual labeling is used to meet legal requirements and customer demands for traceability. More flexible and fully automated production and assembly processes are increasing the need for clear identification of components and assemblies. Downstream processes such as lasering, labeling, printing or embossing are state of the art. In order to be able to reduce work steps, cycle-integrated processes such as in-mold decoration are chosen. As part of the KMU innovativ joint project "Plastic packing Unique Device Identification System" (PUDIS), solution strategies for marking components directly in the injection molding process are being developed. In the project a prototypical realization of such a marking system is developed. The marking system consists of a marking module, a control unit, a scanning module and a corresponding user interface. A three-dimensional code is generated via the marking module, which is integrated in the injection mold, and molded directly onto the component during the original molding process in the injection mold. The design of this marking module is subject to various challenges in view of the high temperature and pressure intensities within the cavity of the mold. The overall system ensures clear identification and traceability of the plastic parts produced. A feasibility study carried out with a reduced functional scope was able to confirm the assumptions underlying the project and show that the marking module can withstand the conditions prevailing in the cavity and form a reproducible marking in the part. The project team was able to achieve these successes after implementing the marking module in the injection molding machine on 2 needles. The markings on the injection molded parts were measured tactilely and optically. Needle 1 and 2 cover a distance of about 0.4 mm from the 0-state to the 1-state. It was demonstrated that there is no displacement of the needles despite the high cavity pressure. A database for the decoding algorithms was obtained based on the components produced in the experiments. In the later course of the project, tests are to be carried out with all 25 needles and complete codes generated. The components will then be evaluated and analyzed via the evaluation software. Once all systems are functioning, long-term tests will be carried out to validate the system for series production. The aim of the project is to enable in-situ marking in plastic components. The requirements for the marking module used for this range from the smallest possible installation space to a modular design. Furthermore, a software for the evaluation of the introduced coding is being developed. KOMDRUCK AG, Formconsult Werkzeugbau GmbH and Schmalkalden University of Applied Sciences are involved in the PUDIS project.

About the Presenter

He is working in Applied Plastics Engineering at Schmalkalden University of Applied Sciences on the topic of product development and injection mold design, especially for multi-component applications, Filling pattern simulation for thermoplastics Temperature control concept development for conventionally and generatively manufactured components and Investigations into the selective influencing of the crystallinity of semi-crystalline plastics.

He is a doctoral student and research assistant at Schmalkalden University of Applied Sciences.

Abstract

Due to insufficient sorting and recycling, macroscopic contaminations remain in post-consumer polyolefin recyclates. It is known that these contaminations affect the mechanical properties of the recyclates, as they constitute defects and thus crack initiators. However, the influences of different types and amounts of macroscopic contaminants have not yet been analyzed systematically. In this study, to close this knowledge gap, virgin polypropylene (PP) was systematically contaminated with paper, aluminum, sand, wood, in-mold labels, jute fibers and long glass-fibers. Additionally, three commercially available post-consumer PP recyclates were investigated. In a two-stage process, all materials were injection-molded into plates and subsequently milled to specimens. The specimens underwent (i) tensile tests at 50 mm/min, (ii) intermediate-rate tensile tests at 2000 mm/min, and (iii) tensile impact tests. Further, optical microscopy was used to measure the dimensions of the defects on the fracture surfaces. First, the influences of various types and quantities of contamination were evaluated. No significant effects were detected, as the matrix material was very brittle. Compared to the virgin reference grade, most samples showed lower strain-at-break values, except for those with labels and long glass-fibers, for which strain values increased. All PP post-consumer recyclates exhibited a more pronounced ductile behavior, although the contaminations incorporated gave rise to relatively high standard deviations. Second, in a comparison of various testing speeds, a greater influence of contaminants was detected in test (iii). Samples taken from a position close to the sprue had better mechanical properties than samples taken from the opposite side of the plate, as contaminants tend to flow to the end of the produced part. Finally, a non-linear relationship between the energy needed for fracture in testing methods (ii) and (iii) and the dimensions of the contamination on the fracture surface was found.

About the Presenter

Ines finished her Master's degree in Polymer Technologies and Science at the Johannes Kepler University in Linz (Austria) in 2020. The Bachelor and Master Thesis were done in the field of solar energy dealing with the development and evaluation of stabilizers needed for a high endurance time of solar thermal systems and photovoltaic modules. Since then she is working on her PhD Thesis in the field of recycling of polyolefin waste at the Competence Center CHASE (Austria).

Abstract

A variety of questions may arise in the UV-curing process of polymeric materials. For example, when does UV-curing start? When is UV-curing complete? What is the reactivity of the resin? What is the glass transition temperature after curing? Which photo initiator does show best performance? How does mechanical property of the cured material change in UV-curing process? Differential Scanning Calorimetry (DSC), Dielectric Analysis (DEA) and Dynamic Mechanical Analysis (DMA) offer effective means to help to answer these questions. DSC measures reaction enthalpy and degree of cure initiated by radiation. DEA allows for the measurement of changes in the dielectric properties related with ion mobility and dipole alignment during cure. Compared with DSC, DEA is good for fast cure system because data acquisition rate is less than 5ms and more sensitive to small change in cure process when close to the end of cure. DMA measures modulus changes during UV-curing process. These thermal analysis methods are indispensable in both R&D and quality control in the area of UV cure.

About the Presenter

Yanxi Zhang received her PhD from University of Alabama at Birmingham under the direction of Professor Sergey Vyazovkin in 2007. After obtaining her PhD in Chemistry she worked as a postdoctoral associate at Rensselaer Polytechnic Institute and Case Western Reserve University. Now she works with NETZSCH Instruments North America, LLC as Technical Sales Support. She is focused on polymer characterization for more than 15 years by thermal analysis and kinetic analysis. In her current role she makes many oral presentations at technical conferences. She also peer-reviewed over 100 manuscripts in the field of polymer and thermal analysis for scientific journals from Elsevier, etc.

Abstract

The low recycling rates of post consumer polyolefins has origins in thermodynamics. Polyolefins enter the recycling stream in mixed form, and are subsequently melt processed as blends. Due to thermodynamic incompatibilities they form micro-domains and upon subsequent cooling, crystallize in a cascading fashion, frequently with poor interfacial adhesion - causing brittleness. While such cascading crystallization is critical to the final mechanical properties. it is poorly understood. Here we employ multi-modal methods (rheology, Raman, x-rays and calorimetry and optical microscopy) to study the crystallization kinetics and associated rheology in immiscible blends of high density polyethylene and isotactic polypropylene, both under quiescent and shear conditions. We find strong differences in polypropylene crystallization as a function of molar mass, composition and shear – with domain morphology playing a major role. Our results indicate the importance of rheology and processing on the structure and ultimately the properties of mixed waste-stream crystallizing polymers.

About the Presenter

Dr. Kalman Migler is a staff scientist at the National Institute of Standards and Technology, where he currently leads the project on rheology and processing of plastics recycling. His primary interest is in the measurement of non-equilibrium phenomena that occur during polymer processing and rheology. Throughout his career he has developed technologies to measure polymer blend extrusion, polymer processing instabilities, fluoropolymer additives, polymer slippage, carbon nanotube composites and crystallization. He is a Fellow of the American Physical Society, the Society of Rheology and the Washington Academy of Sciences.

Abstract

The use of fossil resources and their negative environmental impacts has awakened the awareness of the petrochemical industry. Hereby, we are presenting some upstream industrial scalable and commercial solutions to process sustainable feedstocks, either biogenic or recycled, to produce drop-in hydrocarbons that can be converted into light olefins using the same assets and infrastructure currently established in the petrochemical industry (e.g. steam crackers), reducing the environmental impact of large-volume chemicals such as ethylene, propylene and benzene, which are the most demanded building blocks in the petrochemical value chain. Mass balanced certified co-processing of biogenic and recycled waste plastics as raw materials, are the key for the de-fossilisation of the petrochemical industry. Production of polypropylene (PP) using renewable feedstock can reduce the GHG above 80% or 3.8 kg CO2eq/kg in comparison with the fossil-based. For making a higher impact in the plastic industry, a full integration of the value chain is needed to guarantee allocation of the sustainable credits to targeted products. As a showcase, a collaboration project between partners in different parts of the value chain to produce biobased PP thermoformed plastic cups, is presented. As a result from this collaboration, PP cups with final properties identical in range to the traditional fossil were obtained and the renewable hydrocarbons could be identified in the product using C14. Drop-in solutions using renewable or recycled feedstock is paving the way in the petrochemical industry to obtaining sustainable products with low impact in the current downstream infrastructure.

About the Presenter

Dr. Oscar Vernaez: Polymer Specialist with PhD in Chemistry from the Pau University in France and a PhD in Engineering from the Simon Bolivar University in Venezuela. After 12 years as researcher and Project manager in the Technological Center INTEVEP of the national petroleum company in Venezuela (PDVSA), he worked three years as group leader of Material development in the bioplastic department of Fraunhofer UMSICHT in Germany. Currently is working as research and development manager for Chemicals and Materials at Neste. His team brings technical support to Neste's business unit of Renewable Polymers and Chemicals and the innovation business platforms.

Abstract

The PET Stretch Blow Mold package development process timeline is highly dependent on the ability to attain functional PET bottle prototypes for evaluation and analysis. The conventional process requires subtractive manufacturing and assembly of a metal mold set, with typical lead times taking as long as 4 weeks. Prior attempts by industry to fast track the process utilizing Additive Manufacturing methods met with very limited success, as less than 100 samples were capable of being produced. The purpose of this research is to achieve an Industry breakthrough in PET SBM functional sample prototyping, aiming to go from concept to manufacturing in five days, by applying advanced Additive Manufacturing capabilities, through the selection of engineering photopolymer resins and a novel Stretch Blow Mold modular mold tool construction.

About the Presenter

Thangthip Tekanil is a Sr. Engineer at PepsiCo Global Beverage Packaging R&D within the Advanced Design & Engineering Group. She currently leads the Advanced Rapid Prototyping Strategy pillar for the Beverages Category, and works in close collaboration with Packaging Developers, Industrial Designers, and other cross-functional partners to accelerate packaging development and innovation. Thangthip graduated from UMass Lowell with a Bachelor's and Master's degree in Plastics Engineering. Thangthip's interests consist of but are not limited to research and development of polymeric materials, polymer processing technologies (SBM, IM), and additive manufacturing.

Abstract

Mechanical recycling is one of the most economical pathways to reduce the environmental impacts of plastics. High-value, engineered plastics such as polycarbonate (PC) are being recycled at increasing quantities to the point that the supply of high-quality post-consumer recycled (PCR) polycarbonate is seen as an upcoming bottleneck to meet growing demand. There is an urgency to scale recycling of high-value, engineered plastics from the waste stream into new electronics. Accessible sources of recycled PC are still limited to select applications such as headlamps, construction sheets, and water barrels. In order to utilize material from additional waste sources, focus needs to be on addressing complicated waste types (PC with additives or PC-blends), reprocessing approaches to remove contamination (metals), and development of robust performance recycled content plastics. Mixed-plastic waste is commonly downcycled today and presents many challenges for the value chain from re-processing to the scale of e-waste collection. It is encouraging that many electronics brands have created take-back programs to increase collection rates and support scaling recycling technologies. However, today only a fraction of the electronics manufactured enter the recycling stream. Lack of volume and consistency in waste material streams present another challenge for the industry. Dell, Covestro, and MPT together investigated the effects on material properties, processing, and component quality levels through multiple rounds of simulated closed-loop recycling with positive results. A PC/ABS + talc blend was used as the base production material to add reground scrap parts and mold new laptop components. A total of three recycling loops were tested (equivalent to ~32 years), increasing regrind content by 20% each loop. Impacts of UV monocoat paint on the recycling process were also examined. Results showed the material could be recycled several times and still retain high performance. Paint had a minimal impact on the recycled material performance. Closed-loop recycling of PC and PC blends can offer an efficient pathway to recycle laptop plastic materials. The recycling process from collection, dismantling, and sorting is critical to influence the quality of e-waste to be further developed for second-life use. Laptop brand manufacturers also use a common framework of materials primarily based around polycarbonate and polycarbonate blends, creating an opportunity for scale. Circular design principals must be considered for long-term recycling success and support circular e-waste models.

About the Presenter

Allison Ward is a sustainable materials engineer in Dell's Experience Design Group. With a background in material science engineering and supply chain development, she specializes in strategic circular material programs to support Dell's sustainability goals. She holds a bachelor's degree in material science engineering and a master's degree in industrial operations engineering from the University of Michigan.

Dr. Nicolas Sunderland is a Senior Principal Scientist at Covestro, where he supports the development and applications of polycarbonate plastic in Electronic and Electrical markets. He obtained his PhD in Chemistry at Penn State University, and has worked for over 20 years in the Plastics Industry in various technical roles, now focusing on the development of sustainable solutions.

Abstract

Polyethylene terephthalate (PET) is one of the most commonly used plastics in our daily life. It is completely recyclable and is the most recycled plastic in the U.S and worldwide. However, recycled PET from different sources may have large variabilities, such as reduced molecular weight, broader molecular weight distribution, different crystallinity, and containing different impurity contents, all of which can affect their processing and application. This presentation will discuss of using thermal and rheological techniques to fingerprint the feedstock resins and help guide extrusion processing. Specifically, we will discuss using differential scanning calorimetry (DSC) to identify the type of impurities, monitor the effect of thermal history on the crystallinity and crystal melting. We will also discuss using rheological techniques to estimate the molecular architecture, measure melt stability, melt viscosity, and help optimize extrusion conditions.

About the Presenter

Dr. Tianhong (Terri) Chen is a Principal Applications Scientist at TA Instruments. She received her PhD degree in Polymer Science from Sun Yat-sen University (SYSU) in China, where she was specialized in polymer synthesis and material engineering. She did her post-doc research and later became a research assistant professor at University of Maryland. During that time, her research was focused on biopolymer modifications and characterizations. Dr. Chen joined TA Instruments in 2004. Her key responsibilities at TA Instruments are customer support, consultation, and teaching customer training courses. Dr. Chen has more than 50 publications in peer-reviewed journals and 2 US patents.

Abstract

The strength that glass reinforcement can impart to plastic materials is phenomenal. Glass fiber reinforced plastics offer enhanced mechanical properties, particularly strength and stiffness over unfilled materials. Their use is widespread in a wide variety of applications where mechanical integrity is essential. However, this benefit is not without its challenges. This presentation will focus on the investigation of failures of components manufactured from glass fiber reinforced plastics. The goal of a failure analysis is to identify the mechanism and cause of the component failure - to distinguish how and why the part broke. This presentation will explore the challenges unique to glass fiber reinforced materials and techniques that can be used to gain the maximum information from these failures.

About the Presenter

Jeffrey A. Jansen is the Engineering Manager and a Partner at The Madison Group, an independent plastics engineering and consulting firm. Jeff is a proven plastic professional with more than 30 years of experience solving problems and addressing opportunities related to polymeric materials. He specializes in failure analysis, material identification and selection, as well as compatibility, aging, and lifetime prediction studies for thermoplastic materials. Jeff has performed over 5,000 investigations, both for industrial clients and as a part of litigation. He is a regular presenter on the SPE webinar series, covering a wide range of topics related to plastics failure, material performance, testing, and polymer technology. Jeff is a graduate of Carroll College and the Milwaukee School of Engineering.

Abstract

Initial situation, problem and motivation. The achievement of future EU and Austrian targets for mechanical recycling rates of plastic wastes and the minimization of the EU plastic waste levy for non-recycled plastic packaging wastes require significant improvements in all individual process steps of mechanical plastics recycling. For example, in order to achieve the EU target of a mechanical recycling rate for plastic packaging wastes of at least 55% by 2030, the output efficiencies in the 3 essential process steps, (a) collection, (b) sorting and pre-processing, and (c) conversion & recovery, must be increased from the current Austrian status of approx. 58% for process steps (a) and (b) and approx. 78% for process step (c), to 80-85% (!) for each of these process steps. Objectives and intended outcomes. Building on the existing competences of the partners involved (11 scientific partners, 14 company partners), a further significant increase in knowledge and competence with regard to the entire recycling process loop is to be achieved through comprehensive and interactive integration and participation of the partners in the research program as an overall objective, which is indispensable for the achievement of the very demanding political target quotas. On the one hand, this knowledge generation relates in particular to necessary process and materials technology aspects and measures, but on the other hand also to logistical requirements for waste and material flow management. From this, 4 concrete main objectives including expected results are derived: (1) to identify and explore further, so far unused potentials for the mechanical recycling of plastics, (2) to define, implement and test key process steps on a laboratory/pilot scale, (3) to demonstrate the eco-efficient "marketability" of increased quantities of recycled plastics through exemplary products with improved quality and performance characteristics, and (4) to demonstrate the principle scalability of the laboratory/pilot processes to production scale (case studies). Innovation content and sustainability. The integrative and coordinated consideration of all process steps in the mechanical recycling of plastics, together with the structure and design of the research program, defined by the selected classes of material flows, plastics and products as well as the process steps to be researched in the individual work packages and the associated effects on the material quality characteristics of the recyclates, form the overarching framework for the "conceptual" innovation content of this flagship project. Important innovation components also result from the use of digital technologies and modern, intelligent sensor technologies. This will enable the technical and the economic-ecological optimization of all process steps along the entire value chain of mechanical recycling of plastic wastes from both separate collection and mixed wastes. In the material flow management, special attention is paid to energy efficiency, the potential use of renewable energy technologies and the recycling of water including any additives (chemicals). The commercial implementation of the research results in future industrial practice is ensured not least by the main objectives (3) and (4) described above.

About the Presenter

Joerg Fischer is a professor in the field of Polymer Engineering and Science at the Johannes Kepler University Linz. As an associate professor at the Institute of Polymeric Materials and testing, he teaches and conducts research in the field of plastics recycling, polymer material development, and the characterization and testing of polymer materials. In his research, he considers the entire value chain of plastics products and he investigates the relationships between the processes and the material property profiles. The focus is on specification-relevant property profiles of materials, which is also a relevant perspective for plastics recycling processes. Prof. Fischer is project leader and key researcher in several cooperative research projects. He conducts research with companies along the entire value chain of plastics recycling, starting with waste management companies, over plastic recyclers and plastics product manufacturers and ending with brand owners and retailers.

Abstract

Compounding is a science. It requires a great knowledge of Chemistry, Formulation, Processing, Equipment and the Human Factor and most recently Artificial Intelligence. Compounders of today are facing many challenges that their predecessors did not face. Market fluctuation due to global issues, labor shortages as a result of pandemic, force majeure by raw material producers are few of many challenges facing compounders now. Purpose of this presentation is to show how you can use AI in your compounding operation and potentially increase your efficiency by at least 25%.

About the Presenter

Saeed Arabi is an engineering manager at Alterra Plastics. Saeed started his career in June 2020 as a process engineer in Alterra Plastics. Saeed holds a B.S. and M.S. Degree in Chemical Engineering from University of Tehran and a second M.S. Degree in Chemical Engineering in Process design from University of Nevada-Reno.

Abstract

Orange peels have high cellulose content and they are available in good quantities. The present study was aimed to produce bioplastic composite based on orange peels. Orange peels were ground using a semi-automatic grinder before the pre-treatment step. The peels were immersed in a 15% sodium hydroxide NaOH solution for 4 hours at 60°C to remove the lignin, hemicelluloses, and other pectic substances. Then, they were neutralized with 1% acetic acid before being washed with distilled water and dried overnight at 60°C in a convective oven. Different natural additives, including starch, glycerol, agar-agar, and D-sorbitol, were added to the orange peels to develop the bioplastic material for optimized mechanical and plasticizing properties. To enhance the mechanical properties of the orange peels bioplastic, calcium carbonate was used in different weight percentages. The ultimate tensile strength of the orange peels bioplastic samples increased from 0.9 MP to 2.4 MPa by the addition of 8 wt% calcium carbonate. On the other hand, the fracture point decreased from 20% to almost 13% strain by the addition of calcium carbonate, the bioplastic become more brittle as the weight percentage of calcium carbonate increases. The bending tests showed that the maximum deflection achieved before fracture is equal to 12 mm and that the specimen can withstand forces up to 6.2 N. This indicates that the achieved biomaterial has a remarkable bending strength and can withstand up to 6.2 N before fracture, proving that it has a strong bending behavior. The deflection decreased by about 20% when 8 wt% of calcium carbonate existed in the matrix and the bending withstand force reduced to about 5.0 N. It is expected that applying a coating layer to the orange peels bioplastic end products makes them more attractive and expands its commercial applications.

About the Presenter

Prof. Deeb Abu Fara, Chemical Engineering Department, University of Jordan

Education

• Ph.D — In Chemical Engineering, McGill University. Montreal, Canada, 1988.
• M.EngIn — Chemical Engineering, McGill University. Montreal, Canada, 1983.
• B.Sc — In Chemical Engineering, Alexandria University, Egypt, 1977.

Research Areas of Interest

• Polymers for medical and pharmaceutical applications:
  • Controlled drug release
  • Polymers for pharmaceutical excipients
• Polymer Engineering and processing
• Biodegradable polymers
• Process dynamics and Control
• Neural network control systems
• Process Modeling and Simulation

Current Research Projects

1. Upgrading of naturally existing CaCO3 powder for pharmaceutical applications.
2. Developing of chitin-CaCO3 composites.
3. Developing pharmaceutical excipients of chitin from different marine sources.
4. Application of QbD strategy in pharmaceutical industry
5. Structural Analysis and Crystallinity Correlation of Chitins using Different Spectroscopic Methods

Selected Recent Publications

1. Y. Mubarak, D. Abu Fara. Mechanical Properties of Bio-Based Composite from Orange Peels. SPE ANTEC, 2023.
2. M. Dudeen, D. Abu Fara, M, Allawzi. Modeling and Simulation of the Startup of the Coupling Reactor for an Industrial Scale Production of Diethyl Oxalate. Journal of King Saud University – Engineering Sciences. Accepted, May 2022.
3. Linda Al-Hmoud, Deeb Abu Fara, Iyad Rashid, Babur Z. Chowdhry, Adnan A. Badwan. Influence of Chitin Source and Polymorphism on Powder Compression and Compaction: Application in Drug Delivery, Molecules 2020, 25, 5269; doi:10.3390/molecules25225269
4. Deeb Abu Fara, Linda Al-Hmoud, Iyad Rashid, Babur Z. Chowdhry, Adnan A. Badwan A New Perspective of Multiple Roller Compaction of Microcrystalline Cellulose for Overcoming Re-Compression Drawbacks in Tableting Processing, Applied Sciences, 11 (2020) 4809-4787, 10.3390/app10144787
5. Deeb Abu Fara, Iyad Rashid, Linda Hmoud, Shatha al-Qatamin, Babur Z. Chowdhry, Adnan A. Badwan, Enhancement of compression and compaction properties of calcium carbonate powder by granulation with HPC, HPMC, and Na-alginate as binders for pharmaceutical applications: an optimization case study. J. of Excipients and Food Chemicals. 11 (2) 2020.
6. Deeb Abu Farah, Linda Al-Hmoud, Iyad Rashid, Babur Z Chowdhry, Adnan Badwan. Understanding the Performance of a Novel Direct Compression Excipient Comprising Roller Compacted Chitin. Marine Drugs. 2020, 18, 115; doi:10.3390/md18020115
7. Deeb Abu Fara, Suha M. Dadou, Iyad Rashid, Riman Al-Obeidi, Milan D. Antonijevic, Babur Z. Chowdhry, Adnan Badwan. A Direct Compression Matrix Made from Xanthan Gum and Low Molecular Weight Chitosan Designed to Improve Compressibility in Controlled Release Tablets. Pharmaceutics 2019, 11, 603; doi:10.3390/pharmaceutics11110603.

Reviewing Activities for Scientific Journals

• Polymers and Polymer Composites
• Arabian Journal for Science and Engineering
• Engineering and Applied Sciences
• Dirassat Engineering Sciences, University of Jordan
• Mutah Lil-Buhuth wad-Dirasat, University of Mutah, Jordan

Abstract

In nature, some marine organisms, such as Cephalopods, have evolved to possess camouflage traits by dynamically and reversibly altering their transparency, fluorescence, and coloration via muscle-controlled surface structures and morphologies. To mimic these display tactics, we designed a series of scalable, simple, and low-cost elastomer-based composites, which exhibit similar deformation controlled surfaces to realize various mechanochromisms, including: transparency change mechanochromism, luminescent mechanochromism, color alteration mechanochromism, and encryption mechanochromism. Based on similar elastomer-based composites, a series of moisture and/or laser responsive wrinkle dynamics inspired by human skin featuring different reversibilities and stabilities were also designed and fabricated. These unique responsive dynamics resulted in the invention of a series of responsive materials triggered by moisture and/or laser, whose response can be either reversible or irreversible by tailoring the dimension, morphology, and/or composition of the hybrid structure. The above multifunctional biomimetic elastomer-based composites are promising for applications in smart windows, dynamic optical switches, encryption, anti-counterfeit tabs, water indicators, etc.

About the Presenter

Dr. Luyi Sun is a professor in the Department of Chemical and Biomolecular Engineering. Dr. Sun’s current research focuses on the design and fabrication of polymer-based hybrids for various applications, with a focus on microstructure control via novel processing. He has published more than two hundred eighty peer-reviewed journal articles. He holds twenty-four US patents and over fifty foreign patents.

Abstract

A novel type of foam can form when blowing or frothing is applied to aqueous particle dispersions in the presence of small amounts of a water-immiscible secondary liquid. If the particles have sufficient wettability for both liquids, the process yields a foam in which coated bubbles are embedded in a tenuous network of particles bridged by the secondary liquid and stabilized by capillary forces. First discovered in 2014, these so-called capillary foams show unusual stability and rheological properties in the liquid state. They also provide new avenues for the production and customization of solid foams. The secondary liquid component can be chosen from wide variety of options, including monomers and prepolymers, polymers solutions, waxes and melts. Along with this choice comes a variety of options to solidify the foam, which includes thermal or UV curing, interfacial polymerization or precipitation, solvent extraction, and cooling; these choices largely determine the foam's mechanical properties. The solid dispersion particles, which can be polymeric or inorganic, can impart additional functionality to the foam, such as magnetic, UV absorbing, heat conducting, or antimicrobial properties, to name just a few. Solid capillary foams can be made using materials commonly found in plastics and technical foams, but they can also be based on biocompatible, biodegradable, or even edible ingredients. In this presentation, I will briefly review the structure and material properties of capillary foams known so far and discuss the broad development opportunities of polymer composite foams for a variety of applications.

About the Presenter

Sven Behrens is a Managing Scientist at the engineering and scientific consulting firm Exponent. He holds a diploma in Physics from Goettingen University (Germany) and a Ph.D. in Environmental Sciences from the Swiss Federal Institute of Technology (ETH) in Zurich, Switzerland. After two years of postdoctoral research at the University of Chicago and five years of industrial research in the polymer research division of BASF, Germany, he worked as an Associate Professor of Chemical Engineering at the Georgia Institute of Technology from 2007 to 2020, with tenure since 2013. Since 2020, he has been working as a consultant in the Practice of Polymer Science & Materials Chemistry at Exponent while retaining an adjunct faculty position at Georgia Tech.

Abstract

The transition from internal combustion to electric vehicles has uncovered a multitude of technical challenges. One challenge that has a direct impact on how consumers perceive the value of a vehicle is its overall quietness and comfort. It is well known that the elimination of an internal combustion engine, which masked most of the noise, has resulted in an increase in cabin noise. The sources of this noise can be either from environmental (wind, tire, road noise) or from structural (electric motors or drives) vibration. In an effort to reduce the structural vibrations – OEMs have investigated routes to isolate or reduce these vibrations through engineering (design) approaches. As a material supplier, we have approached this challenge from the material level, by designing a novel copolymer that inherently absorbs structural vibration. This presentation will discuss the technical challenges and the approach in the development of a polyamide solution that can dampen structural vibration and will showcase the design space that allows us to address the various operating conditions of the application.

About the Presenter

Dr. Bradley Sparks is a Development Manager, where he manages a group of Product Development Scientists in the Engineering Materials group at Ascend Performance Materials. He received his doctorate in Polymer Science and Engineering from the University of Southern Mississippi.

Abstract

In addition to polymers based on non-fossil feedstocks that help reduce carbon footprint or blends that incorporate recycled content to reduce waste, there additional strategies a manufacturer can pursue to further lower energy consumption and material usage. In this presentation, we delve into polycarbonate materials chemistry and property profile to point out cases where the material and process innovations come together to maximize productivity and lower energy consumption or even lower material consumption to reduce waste. How these fit together in a greater context of plastics manufacturers looking to be part of an emerging circular economy will also be discussed.

About the Presenter

With over 20 years technical experience with Polycarbonate resins, Pierre heads Global Technical Marketing for Healthcare at Covestro’s Engineering Plastics Business and the Healthcare area for over 10 years. Pierre is the current Secretary of the Medical Plastics Division. Pierre earned a Ph.D. in Chemistry from Carleton University in Ottawa (Canada).

Abstract

Economic and environmental costs are assessed for four different plastics manufacturing processes, including stock and upgraded material extrusion 3D printers, as well as cold and hot runner molding. Characterization indicated the larger stock 3D printer had a melting capacity of 14.4 ml/h while the smaller but upgraded printer had a melting capacity of 36 ml/h. 3D printing at these maximum melting capacities resulted in specific energy consumption (SEC) of 16.5 and 5.28 kWh/kg, respectively, with the latter value being less than 50% of the lowest values reported in the literature. Even so, analysis of these processes found them to be only 2.8 and 3.5% efficient, respectively, relative to theoretical minimum energy requirements. By comparison, all-electric injection molding with a cold runner mold had a specific energy consumption of 0.205 kWh/kg and was 54% efficient relative to the theoretical minima. Breakeven analyses considering the cost and carbon footprint of mold tooling found injection molding provided lower costs at a production quantity around 70,000 units and a lower carbon footprint at a production quantity around 10,000 units. Parametric analysis of model inputs indicates that the breakeven quantities are robust with respect to carbon tax incentives but highly dependent on mold costs, labor costs, and part size.

About the Presenter

David Owen Kazmer is past Chair of Plastics Engineering at the University of Massachusetts Lowell. He performs teaching and research in model-based product and process design. He is the recipient of twenty different recognition awards, including Fellow of the Society of Plastics Engineers, Fellow of American Society of Mechanical Engineers, Ishii-Toshiba Design for Manufacturing Award, U.S. Department of Energy Innovative Process Award, and the Lincoln Electric National Design Competition. He is an inventor with over 20 patents, the author of more than 300 publications including two books, and a member of the Machinery's Handbook Editorial Board. Dr. Kazmer received his B.S. Mechanical Engineering from Cornell University and his doctorate from Stanford University's Mechanical Engineering Design Division. His academic research is motivated by industry experiences in engineering and management at General Electric and Dynisco.

Abstract

The behavior of materials confined at the nanoscale has been of considerable interest over the past several decades, especially changes in the glass transition temperature (Tg) and/or melting point (Tm). Less well studied are the effects of nanoconfinement on polymerization kinetics and thermodynamics. Our recent focus has been on understanding how nanoconfinement influences various classes of polymerizations, including the step growth reactions of thermosetting resins, the free radical reaction of various methacrylates, and the ring-opening polymerization of dicyclopentadiene. We find that changes in reaction rates under confinement can generally be explained by a competition between changes in local packing, diffusivity, and surface effects. The result is generally, but not always, an acceleration of the rate of the nanoconfined polymerization. In addition, nanoconfinement influences the chain length, PDI, and tacticity of the synthesized polymer, making confinement a potential tool for controlling synthetic outcomes. Finally, in the case of equilibrium polymerizations, nanoconfinement influences the monomer/polymer equilibrium shifting it back towards monomer, and this effect can be exploited to determine the entropy loss on confining a chain and to test scaling theories in the literature concerning confinement entropy.

About the Presenter

Simon received her B.S. in Chemical Engineering from Yale University in 1983, followed by three years at Beech Aircraft working on the all-composite Starship. She received her Ph.D. in Chemical Engineering from Princeton University in 1992. She took her most recent position at North Carolina State University in 2021 and is Distinguished Professor and Head of Chemical and Biomolecular Engineering. She has numerous honors, including the Society of Plastics Engineers International Award, the Society of Plastics Engineers Research Award, and the Lifetime Achievement Award of the North American Thermal Analysis Society. She has also been named a Fellow of the American Physical Society, the Society of Plastics Engineers, the North American Thermal Analysis Society, and the American Institute of Chemical Engineers.

Abstract

In the frame of polar, deep water, and exoplanet exploration, lightweight multifunctional materials with durability targeting extreme environments are highly sought. Specifically, mechanical strength and a high degree of thermal insulation are among the most critical properties of structural materials in these applications. Mechanical strength imparts the structural integrity needed to minimize damage to sensitive electronic components, while thermal insulation is needed to protect equipment in extreme temperature conditions. Herein, this work uses micro/nano-layered technology to fabricate film/foam alternating structures for an advanced structural architecture that combines the mechanical performance of multilayered materials with the thermal insulation properties characteristic of polymer foams. We used PC as the film layer, PMMA as the foam layer, and CO2 as the foaming agent. With respect to foam structure, our work demonstrates that due to the confinement effect of the film layers, samples expand only in the thickness direction with no noticeable expansion along the in-plane direction. The apparent expansion ratio in the thickness direction increases with increasing layer numbers (up to 513 layers), ranging from 2.3 to 11 times expansion. With respect to cell morphology, there is a clear decrease in cell size with increasing layer numbers, with a concomitant increase in cell density. Specifically, we obtain the highest cell nucleation density and smallest cell size, around 1.1×1013 cells/cm3 and 400 nm, respectively, from the 513-layer sample foam, when treated at 70 C and 20 MPa. This micro/nano-layered film/foam alternating system offers an outstanding combination of tensile strength (~33 MPa) and low thermal conductivity (~0.0297 W/m·K), in comparison to foams or aerogels with similar thermal conductivity and tensile strength of less than 1 MPa. The balanced tensile performance and insulation properties offered by this multi-tiered structure open the door for use in applications including the exterior layer of vehicles operating in extreme conditions.

About the Presenter

Dr. Patrick C. Lee received his M.A.Sc. and Ph.D. in Mechanical Engineering from the University of Toronto in 2001 and 2006, respectively. Then he pursued Postdoctoral study in the Department of Chemical Engineering at the University of Minnesota under Prof. Chris Macosko. Dr. Lee began his professional career at The Dow Chemical Company in 2008. He was a Research Scientist in Dow's Core Research and Development organization. Dr. Lee joined the Department of Mechanical Engineering at The University of Vermont as an assistant professor in 2014, then joined the Department of Mechanical and Industrial Engineering at The University of Toronto starting July 1st, 2018. Since joining U of Toronto, he created the research platform on the lightweight composite structures. Dr. Lee has 61 research journal papers, more than 100 refereed conference abstracts/papers, 2 book chapters, and 19 filed or issued patent applications. He is the PI or co-PI on domestically and internationally awarded grants from various government agencies and industries. Among his honors, Dr. Lee received the US National Science Foundation Early Faculty Career Development Award (CAREER) in 2018, the PPS Morand Lambla award in 2018, the Hanwha Advanced Materials Non-Tenured Faculty Award in 2017, 3 "best paper" awards from the Society of Plastics Engineer (2005, 2 in 2011). He also served for ANTEC TPM&F 2019 as the Technical Program Chair.

Abstract

Thermoforming is a widely employed technology for large part manufacturing in the automotive industry, in part because of lower initial tooling costs and the suitability of this process for medium to low production volumes. At present, the industry manufactures EV battery components predominantly through sheet metal forming. This can come with some challenges: use of metal can add significant weight and negatively affect overall performance. Also of significance, metal solutions can present critical heat shielding concerns. Despite all of this, lack of alternate mature large-scale manufacturing processes has kept sheet metal forming as the industry's leading choice. The challenges and limitations of using conventional metal highlight potential opportunities for use of thermoplastics, specifically for battery pack components such as top covers and bottom trays. The latter shows tremendous promise to support weight savings, for extended range, and enhanced thermal runaway protection, for improved safety. Furthermore, thermoplastics can potentially deliver added benefits, such as increased functional integration, enhanced thermal and electrical insulation, etc. To develop such solutions requires a holistic approach combining optimal design, novel material formulations, creative approaches for manufacturability, and methods for sub-system level validation. This session will highlight a study in which a novel thermoplastic composite material ‚Äì a 30% glass-filled, intumescent, flame-retardant (FR) polypropylene (PP) — was used to manufacture a battery pack's top cover, through sheet extrusion and thermoforming. The composite material was first extruded successfully into flat sheets at both pilot scale and commercial scale to exhibit its manufacturability. Next, the sheets were tested under different fire scenarios to assess material performance against thermal runaway conditions. Finally, the extruded sheets were thermoformed into multiple prototype geometries, from small to large-scale — to validate formability of the material for the top cover and similar-sized battery pack parts. Study findings demonstrate the feasibility of extrusion and thermoforming of the thermoplastic composite material for large actual scale components with complex geometric features. In addition, tests show the potential of this same FR glass-filled PP material to withstand the thermal runaway conditions encountered in battery packs so the industry can meet vehicle occupant escape-time requirements.

About the Presenter

Anil Tiwari is a Gold Medalist in Master of Engineering in mechanical from Indian Institute of Science, Bangalore, India. His primary expertise is in application development, structural design, engineering & manufacturability using thermoplastics and hybrid materials for light weighting, performance enhancement and part integration. Currently, Anil is part of Global Application Technology group and he is focusing on development of thermoplastic material solutions for automotive including EV batteries and other segments such as foam and lightweight for packaging application. He holds 15+ U.S. patents and has co-authored more than five publications in reputed international conferences.

Carlos Pereira is a chief scientist with SABIC's global Automotive Technology team. His focus today is on thermoplastic solutions for electric vehicles and autonomous driving. His experience with SABIC crosses various components and systems of vehicles, from under-the-hood applications to interior and exterior trim and aerodynamic exterior parts for heavy trucks. Before joining SABIC in 2014, he held various project engineering roles with RUAG Space, during which time he worked on large satellite composite structures and science experiments for the International Space Station. He also served as an application development engineer in multiple roles for Dow Chemical from 1985 to 1998, building knowledge and expertise in composites and other materials for structural automotive components. He also has application development experience involving materials for industries such as packaging and wire and cable. He holds a bachelor's degree in chemical engineering from Cornell University and advanced studies in material science at the Technical University of Clausthal in Germany.

Abstract

In the present paper, we have studied thermal properties and thermo-chemical stability of a medical-grade adhesive comprised of a cationic, cycloaliphatic epoxy resin system by using differential scanning calorimetry (DSC) and thermo-gravimetric analysis (TGA) techniques. Then, we have explored UV curability of the adhesive by performing a series of the UV-cure experiments using special photo-DSC (or p-DSC) technique and investigated relevant relationship of resultant thermal properties and thermo-chemical stability of such UV-cured adhesive materials with the underlying UV irradiances during UV curing. Thereafter, we have further examined thermal curability for various post-UV cured adhesive materials by conducting a series of the thermal-cure experiments and measured the ultimate glass transition temperatures of resultant adhesive materials at various "fully-cured" states with using a conventional DSC technique. According to these thermal analysis tests, p-DSC UV-cure experiments, and DSC thermal-cure experiments, we are able to thoroughly understand effects of UV irradiances applied during UV curing on dual UV-thermal curability and resultant thermal properties of various resultant adhesive materials at the "fully-cured" solid states to provide pertinent scientific insights on relevant adhesive handling and processing operations in making medical devices.

About the Presenter

Xiaoping Guo is currently a Senior Associate Research Fellow at the R&D Science & Technology, Abbott Laboratories (Electrophysiology Division), St. Paul, Minnesota. As a polymer specialist, he provides relevant technical services on Polymer Engineering & Science in support of product designs, advanced process development, post-market product analysis, and biological assessment of medical devices, and etc., across various medical device divisions in Abbott. He also conducts innovative polymer material development with specialty applications in novel medical devices, and performs a variety of in vitro and in vivo biostability studies of medical polymers for medical devices. Dr. Guo obtained his Ph.D. degree in Polymer Engineering from the College of Polymer Science & Polymer Engineering, The University of Akron, Ohio, in 1999.

Abstract

This study describes a detailed analytical characterization of polyaryletherketone (PAEK) polymers used in extrusion-based additive manufacturing. The results provide key observations and highlight differences between commercially available polymers of the PAEK family, specifically polyetheretherketone (PEEK) and polyetherketoneketone (PEKK). Results suggest that inherent differences in their molecular structure lead to notable differences in terms of their viscoelastic, thermal and physical properties. Similarly, direct comparison of the properties between parent filaments and three-dimensional printed (3DP) parts suggests that, as observed in subtractive processes, the molecular structure of the PAEK polymer selected (PEEK or PEKK), as well as the inherent physical properties associated with it, determine greatly the performance of final 3DP parts. Differential scanning calorimetry results suggest that the glass transition temperature (Tg) of PEEK 3DP bars (146.8°C) is about 8°C lower than that of the parent PEEK filament (154.8°C). These small differences manifest greatly in the viscoelastic response after Tg, and the temperature at which a decrease in storage modulus is observed occurs consistently at lower temperatures in 3DP PEEK bars (ca 130°C) compared to PEEK filaments (ca 150°C). In contrast, no observable differences are noted between parent filaments and 3DP bars in PEKK polymers. For these polymers, the inherent semi-crystalline behavior dominates their thermal and viscoelastic response. These structure-property relationships provide fundamental understanding to aid in the design and manufacturing of several industrial and biomedical applications that could potentially leverage the advantages of high temperature thermoplastic PAEK resins, as well as in the incorporation of these polymers in a growing number of technologies encompassing the field of additive manufacturing.

About the Presenter

Dr. Streifel is a Managing Scientist at Exponent’s Polymer Science and Materials Chemistry practice. Dr. Streifel specializes in the design, synthesis, and characterization of hydrogels, foams, block copolymers, and semiconducting polymers. Dr. Streifel has utilized a wide variety of techniques for the design, synthesis, and characterization of polymeric materials, including spectroscopy (UV-Vis, FTIR, and Fluorescence), mechanical and thermal analysis (DMA, rheology, DSC, and TGA), chromatography (GPC, GC-MS, and HPLC-MS), microscopy (optical and SEM), and nuclear magnetic resonance spectroscopy (NMR). Dr. Streifel received a Ph.D. in Chemistry from Johns Hopkins University in 2014 focusing on the synthesis and characterization of semiconducting polymers for energy generation and spintronics applications. Prior to joining Exponent, Dr. Streifel worked as a National Research Council Postdoctoral Research Associate at the Naval Research Labs in Washington, DC. While there, he designed, synthesized, and characterized materials for the treatment of severe wounds.

Abstract

Ultra-stable glasses, either made by vapor deposition or through extreme aging as in natural amber, provide an avenue to explore otherwise unattainable regions of the deep glassy state. Here we show evidence from a vapor deposited (through vacuum pyrolysis deposition [VPD]) amorphous fluoropolymer and for a 50 million year old amber from Fushun China that glasses can be made that have fictive temperatures TF below the putative Kauzmann temperature TK. In the case of the VPD fluoropolymer, we find from flash differential scanning calorimetry measurements that the fictive temperature is approximately 11.4 K below the Kauzmann temperature as estimated from the VFT singularity temperature determined from the cooling rate dependence of the TF. In the case of the Fushun amber, we used length change dilatometry to determine the fictive temperature of the as-received material as well as to establish the glass transition temperature Tg upon cooling at 2 K/min. In this case the Tg was found to be 463.2 K and the fictive temperature, obtained from the intersection of the rejuvenated liquid line and the glass line of the as received material, was TF=270.2 K, i.e., some 193 K below the Tg. Given that amber is a polymeric material, one would anticipate that the VFT temperature would be approximately 50 to 70 K below the Tg. Using this is as the surrogate for the TK we then see that this ultra-stable amber has a fictive temperature far below TK. Similar to the findings of the VPD perfluoropolymer, this challenges the importance of the Kauzmann temperature as a driver of glass-formation. In addition, for the Fushun amber, we carried out additional experiments in which the viscoelastic response was determined for a range of glassy states that were obtained by partial devitrification steps. Three important findings were obtained. First, in the regime where T>TF, the upper bound relaxation times were always shorter than expected from a VFT type of extrapolation of the data, consistent with prior work on a 20 million year old amber and on a VPD amorphous Teflon. Second, we were able to perform experiments in the condition where T=TF, i.e., where the dynamics should be equal to those obtained in equilibrium at the specific value of T,TF. In this case the relaxation times not only did not diverge, but unlike prior work we were able to also show that they are exponential in the temperature rather than Arrhenius in temperature. This novel finding is not consistent with any current theory of glasses or super-cooled liquids. Third, because we were able to work so far below the glass transition temperature we accessed relaxation times as long as yotta seconds (1e24 s) which would correspond to a viscosity of over 1e33 Pa-s upon assuming a simple Maxwell model. Clearly, these data show that there remains much to be learned of the extremely deep glassy state. One important point is that understanding such behavior is related to our ability to formulate appropriate equilibrium models of glasses, thus forming the basis of non-equilibrium theories that are needed for lifetime predictions in applications of glasses, which are nearly invariably out of equilibrium.

About the Presenter

Gregory B. McKenna received his B.S. in Engineering Mechanics in 1970 from the U.S. Air Force Academy, a S.M. in composite materials MIT in 1971. From 1971 until 1975 he was stationed at Hill Air Force Base in Ogden Utah, where he served as a Test Evaluation Engineer. In 1975 he left the Air Force at the rank of Captain. While in Utah, he also obtained a Ph.D. in Materials Science and Engineering at the University of Utah, graduating in 1976. After working as a post-doc at the National Bureau of Standards (NBS) for a year, he took a permanent position and worked at NBS (now NIST) until 1999 when he moved to Texas Tech University as a Professor of Chemical Engineering and the John R. Bradford Endowed Chair in Engineering. In 2021 he moved to the Department of Chemical and Biomolecular Engineering at North Carolina State University. Dr. McKenna has earned a reputation as a pioneering researcher in multiple areas of polymers and materials physics and engineering, including physics of glasses, solid mechanics and nonlinear viscoelasticity of polymers, thermodynamics and mechanics of elastomers and gels, and molecular rheology. He has over 260 publications that have been cited over 20,000 times. Dr. McKenna is a Fellow of the American Physical Society, the Society of Plastics Engineers, the Society of Engineering Science, the North American Thermal Analysis Society (NATAS), The American Institute of Chemical Engineers, the American Association for the Advancement of Science (AAAS), and the Society of Rheology. He is the recipient of multiple awards including the International Award from the Society of Plastics Engineers, the Mettler-Toledo Award of NATAS, and the Bingham Award of the Society of Rheology.

Abstract

Natural and synthetic polymeric foams display a variety of open and closed pores with diverse shapes, sizes, and degrees of anisotropy. In state-of-the-art foaming processes, anisotropy in the microcellular structure is produced from an isotropic melt or resin and the imposed confinement in one or more directions to generate anisotropic expansion. As a result, the entire monolith foamed in this way exhibits cells aligned in the direction dictated by the confinement. This, in turn, results in a simple deformational response that is dictated by the loading condition relative to the microcellular orientation. In this work, we investigate the potential of generating a foamed morphology within an anisotropic medium (e.g. film or fiber) to understand how molecular orientation affects the resulting anisotropy in the microcellular structure. In addition, we investigate if we can use this as a strategy to generate complex microcellular hierarchical constructs by using fibers and or films as templates and see how they affect the corresponding deformation. Herein, results are presented to show how assemblies of fibers are woven or twisted with a bias or helical structure and then foamed using superheated water (shH2O) and or supercritical carbon dioxide (scCO2) to manufacture complex microcellular structures. In addition, results from mechanical tests also show how the imposed bias in the foams result in complex deformation imposed by the bias. That is, foams generated to create a helical bias are shown to undergo torsional deformation commensurate with uniaxial deformation when compressed uniaxially. These concepts propose a method to create “smart foams” through the proper assembly of templates (films and/or fibers) that can deform in a variety of different ways, dictated by their overall composite microcellular structure.

About the Presenter

John Daguerre-Bradford is a 4th year graduate student at the University of Massachusetts Amherst in the Polymer Science and Engineering Department under Dr. Alan Lesser. He graduated in 2019 with a degree in Materials Science and Engineering from Virginia Tech, where he conducted research under Dr. Robert Moore and Dr. Johan Foster.

Abstract

A key challenge to the widespread commercialization of fuel cell electrical vehicle, is to design compact and cost effective on-board Compressed Gaseous Hydrogen tanks which store sufficient quantities of H2 without sacrificing passenger and cargo space. The first generation of FCEVs use 700 bar Type IV pressure vessels to store hydrogen. These vessels have a cylindrical BMPL, overwrapped by carbon-fiber composite material to maintain the internal pressure, which serves as a hydrogen gas permeation layer. However, due to its small molecular size, H2 permeates through the plastic liner wall. This represents a serious issue that should be addressed early in the design stage in order to minimize H2 emissions from the liner and conform to legal safety requirements and standards. Meanwhile, automotive OEMs and their suppliers are being challenged to design longer and thinner liners with very consistent wall thickness. One way to meet the hydrogen permeation rate requires a judicious choice of liner material. In the thermoplastic forming industry, it is still common practice to rely on trial and error to find the appropriate barrier layer configuration/thickness required to meet the permeation rate limit requirement. A tool offering a more efficient alternative, based on reliable predictive/virtual analysis of the H2 diffusion through the BMPL wall, could significantly shorten the design/development cycle by allowing product prototypes to be analyzed and tested virtually. A finite element based model that could help a designer better understand barrier layer properties was integrated in the latest version of NRC's BlowView software. The mathematical diffusion model adopted is based on Fick's diffusion law to predict H2 diffusion through a polymeric wall. Promising results, in terms of H2 permeation rate on an industrial BMPL, will presented during the presentation.

About the Presenter

Zohir Benrabah is a Forming and Blow Molding Simulation Scientist at NRC's Automotive and Surface Transportation Research Center in Boucherville, Quebec, Canada, where he is involved in the development of the engineering software, BlowView, dedicated to simulating and optimizing blow molding processes such as: Conventional and Twin Sheet Extrusion, Stretch, Thermoforming, and most recently Suction Blow Molding. Zohir hold a Bachelor and Master degree in Mechanical Engineering and he completed his Ph.D. in 2002 in computational structure at Laval University. He has written over 40 papers on the simulation of thermoplastic forming processes.

Abstract

Multi-component injection molding of liquid silicone rubber (LSR) with thermoplastics, such as PBT or polyamide, is used in the manufacturing process for many components in the automotive industry and in the field of sanitary technology. Due to its hypoallergenic properties, biocompatibility, and resistance to the majority of liquid medications, liquid silicone rubbers are a promising alternative material for use in medical applications. They can be used over a wide temperature range and they are physiologically well tolerated and can be sterilized in various ways. Standard thermoplastics, such as acrylonitrile butadiene styrene (ABS), cannot be overmolded with silicone rubbers in injection molding because of their low heat deflection temperature. With the right production method that combines the processing of silicone rubber and thermoplastics, it would be possible to replace the formerly expensive production and assembly of individual components. Such an integrated production technology makes it possible to realize high-performance new products economically and at the same time, to improve product safety for the patient through simplified, more highly automated and higher-quality production. In this investigation, we applied ABS grades, approved for medical applications, to show how ABS-LSR test specimens regarding the VDI guideline 2019 could be produced using variothermal mold heating and special surface treatment of ABS. Here we will show the development and challenges of a new 2C-molding technology for LSR — thermoplastic parts. For the quality of the later product, the adhesion between thermoplastic and LSR is the decisive feature and depends not only on the injection molding process, but also on the material pairing and the treatment process. Here, we succeeded to manufacture multifunctional products for medical devices through various partial pretratment methods of the thermoplastic surface. In addition, the effect of sterilization (gamma and eto) and artificial aging (humidity and temperature) and of such components on the adhesive bond is indicated.

About the Presenter

Mr. Mohammad Ali Nikousaleh received his bachelor's and master's degree in mechanical engineering from the University of Kassel. During his bachelor thesis, he investigated the "Stereocomplication and Additivation of PLA with a twin-screw extruder". Afterward, in his master's thesis, he continued his research on the influence of UVC irradiation as a surface activation method for bisphenol A polycarbonate to improve adhesion in TP-LSR composites, which was awarded the "Ráchling Prize" at the University of Bayreuth in 2018. Parallel to his studies, he worked on various projects, enabling him to gain more experience in scientific and practical topics. His professional experience in Germany includes working experience at Dow Corning Company (Wiesbaden; Germany) and Alutrim Company (Kyritz; Germany). Since January 2020, he is a research assistant at the University of Kassel and is engaged in multi-component injection molding of liquid silicone rubber.

Dr. Ralf-Urs Giesen studied Mechanical Engineering specialized in polymer process engineering at University of Paderborn/Germany, after that he made his PhD at the University of Kassel/Germany. In 2009 he took up employment as scientific assistant in the Institute for Materials Technology, Department Polymer Technology at University of Kassel/Germany. Currently Mr. Giesen is the managing director of the Polymer Application Center (called UNIpace) of the University of Kassel and also the head of the division UNIpace in the department of Polymer Technology.

Abstract

Environmental pollution caused by increased consumption of non-renewable energy sources has prompted researchers to explore alternative solutions to the global energy crisis. Energy harvesting technology covers the conversion of solar/light, vibration/kinetic, wind/fluidic, magnetic, and thermal energies into electricity, via various mechanisms such as the photovoltaic, piezoelectric, electromagnetic, electrostatic, triboelectric, magnetostrictive, thermoelectric, and pyroelectric effects. Additive manufacturing (AM) provides great opportunities for producing energy harvesters to extract abundant mechanical energy that would otherwise be wasted as heat. Its capability to fabricate structures with complex geometry provides new opportunities to enhance the performance of energy harvesters with individualized design. AM is one of the fastest-growing manufacturing methods that can capitalize its principal advantage of customization by fabricating structures using functional materials. Piezoelectric materials are one such type of functional material desired for their electromechanical behaviours. Poly(vinylidene fluoride) (PVDF) is an electroactive polymer with unique piezooelectric properties due to the presence of polar crystal polymorph (e.g., β-phase) with all dipoles aligned in the same direction (all-trans) zigzag conformation. The ability to additively manufacture piezoelectric material, such as PVDF, opens a new demographic of integrated and personalized smart devices serving from aerospace to biomedical applications. Compared to other AM methods, the fused filament fabrication (FFF) method offers many advantages including cost-effectiveness. Now, many researchers are moving towards FFF to study this process thoroughly. FFF process will be introduced to enable the manufacturing of a device capable of harvesting mechanical energy otherwise lost as heat to the surrounding environment. FFF offers the production of complex and customized geometries that cannot be produced with conventional manufacturing processes. Using FFF to fabricate PVDF devices is still in its infancy with only limited studies available in the literature. In this context, one challenge is to obtain high content of electroactive β-phase within the fabricated PVDF to maximize the materials' electroactive properties.

About the Presenter

Ayatullah Elsayed is a Ph.D. candidate in the Mechanical Engineering Department at York University, Canada. Her research area is additive manufacturing of polymeric smart materials for energy harvesting and sensing applications. She is the holder of NSERC scholarship. Aya's research experience in the field of material fabrication and energy harvesting includes the fabrication of nanotubes, nanofibers, nanoparticles, and several characterization techniques, such as SEM, Raman, XRD, and electrochemical measurement techniques. In addition to the conventional mechanical testing, including tension, bending, impact, fatigue and mechanical wear test. Aya obtained her bachelor's degree in Materials Engineering from Ain Shams University (2012). After graduation, she worked as a research assistant at the American University in Cairo (AUC) on a project for biodegradable polymer composites and their dynamic characterization. Aya obtained her Master's degree from the AUC where she worked on the fabrication and characterization of smart nanomaterials for energy harvesting at Energy Materials Laboratory (EML). During this time, Aya also served as Teaching Assistant in the Design and Production Engineering department at Ain Shams University.

Abstract

Shape memory polymers (SMPs) have great potential and multiple successes for utilization in medical devices and as tissue engineering platforms. Thus, cytocompatible shape memory polymers that are activated to change shape by either heat or light are being actively studied in basic and translational research. By comparison with those traditional activation methods, SMPs that are triggered directly by biological activity have not been reported. Recently, we developed and studied an enzymatically triggered shape memory polymer blend prepared by dual electropspinning that changes its shape isothermally in response to enzymatic activity. We selected a fixing phase that was enzymatically labile so that the temporary shapes – held in place by the labile fixing phase – transformed to permanent shape as a bioinert elastic (memory) phase was liberated to exert its stress. In this presentation we will describe such enzymatic recovery using bulk enzymatic degradation experiments and show that near-complete shape recovery is achieved by degradation of the shape-fixing phase and that the materials and shape recovery process are both cytocompatible. Very recent work on cell-triggered shape recovery exploiting underpinning enzymatic responsiveness will also be presented. Finally, future research and application ideas will be described. The presented research represents a collaboration involving the speaker, Prof. James H. Henderson of Syracuse University, and our students.

About the Presenter

Patrick T. Mather earned B.S. ('89) and M.S. ('90) degrees from Penn State in Engineering Science and Engineering Mechanics, respectively, following which he went on to receive his Ph.D. in Materials at U.C. Santa Barbara in 1994 with dissertation research focused on the rheology of liquid crystals. Following work as materials research engineer for Air Force Research Lab, Mather's academic career has included University of Connecticut, Case Western Reserve University, and Syracuse University, where he helped to create and serve as director of the Syracuse Biomaterials Institute, a sustainable, interdisciplinary effort with 20+ faculty spanning three institutions and seven departments. From 2016 to 2021, Pat served as Dean of Engineering at Bucknell University, where he enjoyed the opportunities and challenges of academic leadership, with a particular focus on inclusive excellence. In 2021 returned to his academic roots at Penn State to become the dean of Schreyer Honors College and professor of Chemical Engineering. Mather's research interests center around smart materials, including shape memory polymers, self-healing materials, polymeric nanocomposites, and biodegradable polymers for medical devices. He is the author of over 160 peer-reviewed papers, inventor on more than 40 patents, and Fellow of both SPE (Society of Plastics Engineering) and the AIMBE (American Institute for Medical and Biological Engineering). Pat is the Editor-in-Chief for Polymer Reviews. He has won several student-nominated teaching awards and prides himself on innovative and engaging teaching methods. Pat and his wife Tara Mather enjoy spending time with their blended family of five grown children (and too many cats to count). You can often catch Tara and Pat out on the road distance running or tandem cycling.

Abstract

A correlation between the steady shear viscosity and complex dynamic viscosity of carbon black (CB) filled rubbers was found by evaluating the Cox-Merz rule and an alternative approach originally proposed by Philippoff for dilute polymer solutions, but since applied to amorphous polymers and concentrated suspensions. This was done by measuring the rheological properties of 16 industrially important rubber mixes containing CB N660 at concentrations of 20 and 35 % by volume. A capillary rheometer at various shear rates and a dynamic oscillatory shear rheometer at small and large amplitude oscillatory shear (SAOS and LAOS) were used. The apparent viscosity, storage and loss moduli, complex dynamic viscosity and Fourier transform harmonics were measured. Generally, the shear stress, storage and loss moduli increased with increasing CB loading. Also, the ratio of 3rd and 5th stress harmonics to 1st harmonics increased with increasing strain amplitude and filler loading. Viscous Lissajou figures (shear stress versus shear rate) at a strain amplitude of 14% showed a nearly linear response for compounds containing CB at 20% by volume. All other shear stress responses demonstrated a strong nonlinearity. The stress waveforms at a strain amplitude of 140% for compounds containing 35% CB by volume displayed a backwards tilted shape expected for highly filled compounds. The stress waveforms at a strain amplitude of 1,000% tended toward a rectangular shape expected for pure polymer. Generally, the nonlinear response of the compounds appeared to be dominated by the filler at strain amplitudes of 14% and 140% and by the rubber matrix at a strain amplitude of 1,000%. The Cox-Merz rule was not applicable for any of the compounds with their complex dynamic viscosity being greater than the apparent viscosity. However, a modification of the approach proposed by Philippoff provided reasonable agreement between the apparent viscosity and complex dynamic viscosity.

About the Presenter

Dr. Avraam I. Isayev is Distinguished Professor Emeritus of Polymer Engineering at University of Akron and former Editor-in-Chief of Advances in Polymer Technology. He is a co-founding faculty member of the department. He received his Ph.D. in Polymer Science and Engineering, Institute of Petrochemical Synthesis of USSR Academy of Sciences, Moscow; M.Sc. in Applied Mathematics, Institute of Electronic Machine Building, Moscow, USSR; M.Sc.in Chemical Engineering, Azerbaijan Institute of Oil and Chemistry, Baku, USSR. Prior to joining the University in 1983, Isayev conducted research at Cornell University, Technion, USSR Academy of Sciences, and State Research Institute of Nitrogenic Industry, USSR. His research interests focus in polymer and composite processing, process modeling, rheo-optics, rheology and constitutive equations of polymers, oil products and disperse systems; the injection, co-injection, transfer, compression and gas-assisted injection molding; processing of selfreinforced or in-situ composites based on blends of flexible and thermotropic liquid crystalline polymers; decrosslinking of thermosets, devulcanization of rubbers and in-situ copolymer formation in immiscible blends with the aid of ultrasonic waves; replacement of petroleum olis in rubbers by modified soybean oils; high temperature and high performance composites and nanocomposites. Isayev has co-authored 4 editions of 1 monograph on rheology, edited or co-edited 8 books, published 274 papers in journals, 37 chapters in books, 8 papers in encyclopedias, 176 papers in conference proceedings. He holds 30 patents. He advised 49 PhD, 42 MS students and 31 postdocs and visiting scientists. He serves on editorial and advisory boards of many journals.

Abstract

The Association of Plastic Recyclers (APR) has published several methods for evaluating the recyclability of polyethylene plastic films. Although the methods are developed for lab-scale process equipment, a large amount of film is typically required for a complete evaluation. To accelerate screening of new film structures and compositions, we have developed a small-scale workflow based on a LabTech Micro Blown Film Line. It only requires 200 grams of materials to blow a film for film properties characterization. In this paper, we will present three case studies to demonstrate this workflow. First case study is the effect of paper label residuals in the post-consumer recyclate (PCR) on the film properties. Second case study is on the recyclability of a PVOH coated film. And the third case study is on the effect of compatibilizer (RETAINTM 3000 Polymer Compatibilizer from Dow) on the recyclability of an EVOH containing multilayer film. The advantages of this workflow are: 1) low materials consumption (200 grams vs > 4 lbs per formulation); 2) fast elimination of formulations that cannot be used in the blown film process; and 3) film properties that provide some indication or ranking of the formulations with different recycle content. Although this workflow may not have high resolution of film properties for complicated film formulations (such as those using a small amount of compatibilizer), it accelerates recyclability assessments for blown film.

About the Presenter

Dr. Jin Wang is a senior research scientist working at Core R&D of the Dow Chemical Company. He is working on technical support and new technology development in the areas of sustainability, blown film, reactive extrusion, foaming, and high throughput research. He is the author of 31 journal papers and the inventor of 16 patents and patent applications.

Abstract

In injection molding, the process is continuously affected by disturbances that influence the part quality. E.g. the processing of post-consumer recyclates (PCR) causes fluctuating process conditions due to a varying composition and history of material batches. PCR consists of recycled polymer material and includes impurities from other polymer types, metals, glass, paper, and others, varying in proportion batch by batch. The fluctuations in part quality grow with increasing recyclate use and lead to reduced mechanical and optical part properties. We developed a phase-unifying process control approach, which combines injection and holding pressure phase by eliminating the switchover point. The approach realizes a given cavity pressure curve by adjusting the screw velocity in real-time. Therefore, a model predictive controller and unscented Kalman-filter are used. Both use a simplified model of the injection molding process to calculate process adjustments correlating to real-time data and predicted process behavior. For the calculation of the cavity pressure reference curve, we used pvT material data in combination with a cooling model. This method decreased batch differences of PCR by more than 50 %. However, a determination of pvT material data is time and cost consuming and therefore not economic. This applies in particular for PCR batches, which are comparatively very small. Therefore, batch differences should be detected during the process to account for online process control. In order to realize process adaptations based on material properties, the objective of presented research is to evaluate batch differences by analyzing process variables, such as screw and cavity pressure, for increasing reproducibility. First, we characterized five different PCR batches to identify the material properties and find fast and cost-effective methods to initialize the controller setting, as controller parameters depend on the processed material. Afterwards, we performed injection molding trials for different process settings to detect batch changes by process analysis. Therefore, we measured cavity pressure, screw pressure, screw position, screw velocity and mold temperature. Finally, we defined part quality and correlated material properties and process data to part quality. Based on the results, a process control concept can be enhanced for automated compensation of batch variations without additional pvT measurements. A consideration of batch-wise viscosity changes is needed for controller parametrization and cavity pressure reference generation. The material characterization showed that the melt flow rate has the highest correlation to part weight, whereas the weight changes cannot be associated with viscosity changes only. The PE content from both, the fourier transform infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC) measurements, had no significant effect on process curve characteristics or part weight changes. Furthermore, batch changes could be identified most effectively by characteristics of the screw pressure curve, which makes an online determination of material batch changes possible.

About the Presenter

Katharina Hornberg was born on 01 July 1994 in Oberhausen, Germany. After graduating from high school in 2013, Ms Hornberg studied mechanical engineering at RWTH Aachen University. In 2014 and 2015, she was a member of the Formula Student Team at RWTH Aachen University, where she gained her first experience of processing plastics. She subsequently decided to specialise in plastics technology in her Bachelor's degree. In 2017, Ms Hornberg completed an internship at the injection molding machine manufacturer Arburg GmbH + Co KG and conducted her first injection molding tests there. Ms Hornberg was enthusiastic about the processing of plastics in injection moulding, so she analysed the geometric and process similarity for transferring machine-learned process knowledge in injection molding in her Bachelor's thesis. From April 2018 to May 2019, Ms Hornberg studied plastics and textile technology in the master's programme with a specialization in plastics technology to expand her expertise in the field of plastics technology and injection molding. In her Master's thesis, Ms Hornberg focused on the development of a process control strategy based on cavity pressure for injection molding. During her Master's studies, Ms Hornberg worked as a student assistant at the Institute of Plastics Processing (IKV) for the entire time. Since June 2019, Ms Hornberg works as a research assistant at the IKV in the injection molding department and is leading the process control working group. Her main area of research involves the development of new process control strategies for the injection moulding process.

Abstract

The impact of melt hardening at low melt undercooling and under atmospheric pressure creates boundary conditions that have yet to be extensively studied since traditional techniques do not require such information. However, for powder bed fusion of polymers, the transition from the melt after exposure to an elastically dominant melt is critical as the crystallization in the building phase occurs under these conditions yielding stresses due to crystallization volume shrinkage. As a result, a process-adapted evaluation is required to determine how long the molten polymer remains viscously dominant, and the point where the stresses are stored in the melt. Therefore, the crystallization of semi-crystalline melt is investigated in this work using rheological data in conjunction with FTIR microscopy. A modified measurement setup of the rheometer with an ATR crystal allows a simultaneous description of crystallization by FTIR spectroscopy and measurement of the rheological behavior of the material. A comparison between the different techniques indicates that the increase in viscoelastic properties during crystallization begins at low degrees of crystallinity. It is determined that the solidification of the melt is detectable at relatively low degrees of crystallization conversion and that no stresses are accumulated in the material until this point.

About the Presenter

Master's degree in mechanical engineering with a major in plastics and laser technology from Friedrich-Alexander University Erlangen Nuernberg, Germany. Visiting scholar at the Polymer engineering center in Madison, Wisconsin under Tim Osswald in 2019. Currently working on completing my PhD in polymer technology at the Friedrich-Alexander University Erlangen Nuernberg, Germany.

Abstract

A differentiable model for non-Newtonian, shear-thinning viscosity is presented as derived by integrating the log-log domain derivative function of the Carreau-Yasuda viscosity model. This work Expands from the discovery of the log-log domain derivative function as this is the foundation for the statement of the new viscosity model. A fitting experiment using polypropylene is performed to illustrate the improvement in viscosity fitting where the shape of the curve in the log-log domain may change with respect to temperature over the assumption of it being constant in the Carreau-Yasuda model for a given polymer. A comparison of pressure drops through two different polymer extrusion profiles and an analytical calculation of pressure drop through a constant cross section, a capillary, and a non-constant cross section, a funnel or conical section, are used to compare the equivalence of the results for shear viscosity. Potential uses for this work include development of explicit or hybrid flow solvers for weakly compressible viscous flows such as polymer melts, and possibly extending to the prediction of effects based on the rate of change of the dilatational (i.e., expansion/compression) and shear parts of the deviatoric strain and strain rate tensors (i.e., viscoelastic behavior) in the flow, although the current model specifically concerns the shear portion only.

About the Presenter

Senior Applications Engineer on the Global Technical Support Team at Altair Engineering, Culver Military Academy (1987), Aquinas College (December 1992) - BA in Philosophy, AAS from Grand Rapids Community College - Plastics Engineering (May 1996), BS in Plastics Engineering Technology from Ferris State University (May 1997). Some coursework after FSU in mathematics and genreal mechanical engineering. Spent 3.5 years setting molds and processing molded parts. Spent 3.5 years in Project and manufacturing engineering. Transitioned from manufacturing engineering in automotive lighting at Lescoa, Inc. into simulation at Hoff & Associates in 1999. In late 2001 moved to Cascade Engineering doing molding and structural analyses. Developed innovative tools for molding during the Cascade years. Moved to Altair in November of 2007. Paul has supported many of Altair's applications over the years and taught classes in both front end applications and several solvers for mechanical, crash, CFD, and Manufacturing solutions. He has developed a Molding Toolkit in Altair Compose to help plastics engineers with a variety of common tasks, and authored a few training classes related to injection molding for Altair, including one due to be launched in 2023, "Polymer Properties for Simulation," which covers properties for simulating with polymers in the context of structures as well as rheological simulation.

Abstract

Polyolefins functionalized with reactive side groups are known to provide improved properties to blends of incompatible resins including processability, homogeneity, and mechanical properties. However, experimentation and use of compatibilizers are limited to virgin based grafted resins, which incurs additional costs for processors. Thus, there is increasing interest in upcycling post-consumer polyolefins to higher value secondary feedstock streams that offer interfacial adhesion of polymer blends. In this work, we propose a melt grafting strategy to achieve reactive functionality and apply the method to post-consumer polypropylene with the purpose of demonstrating recycled polyolefins capabilities as compatibilizers. Experiments are performed using a semi-batch co-rotating micro-conical twin screw extruder at various screw speeds and temperatures. The torque and grafting percentages are controlled by varying the concentration of dicumyl peroxide and maleic anhydride. The functionalized polypropylenes are characterized using spectroscopy and thermal analysis techniques to determine the grafted content and resulting processing behavior. The reactive extrusion process is compared with that for functionalizing virgin polypropylene, and the scale up and economics are discussed.

About the Presenter

Olivia is a M.S. student and Research Assistant studying Plastics Engineering at the University of Massachusetts Lowell. Before attending the University of Massachusetts Lowell, Olivia earned her B.S. in Plastics and Polymer Engineering Technology with a minor in mathematics from the Pennsylvania College of Technology in 2021. Olivia is a member of Dr. Margaret Sobkowicz's research group where her research is primarily focused on mechanically recycling polyolefin waste streams for controlled injection molding applications.

Abstract

Capability studies were performed which compared the use of pressure-controlled and velocity-controlled filling of injection molded parts with plastic that had varying viscosity. A nozzle pressure transducer was used to control the pressure-controlled filling, as well as the pack and hold for both processes. Several methods of transferring from filling to packing were also compared which included screw position, cavity pressure sensors, and in-mold melt switches. This presentation will summarize the results of these studies.

About the Presenter

Brad Johnson has been teaching at Penn State Erie, The Behrend College's plastics engineering technology program since 1994. Prior to joining Penn State, he accumulated over ten years of industrial experience and served in various roles in the plastics industry: manufacturing engineer, manufacturing supervisor, design engineer, and program manager. His primary expertise is in injection molding and process optimization. Along with developing some of the processing classes, he has also taught plastic materials, mold design, rheology, and quality control classes. Brad also directs the Plastics Training Academy (PTA) at Penn State, which offers short non-credit classes on plastics-related topics. He has taught many short classes on injection molding for the PTA, both at Penn State and on-site. He also organizes and chairs the Innovation and Emerging Plastic Technologies conferences that are held in Erie. Brad holds bachelor's and master's degrees in chemical engineering from Virginia Tech. He is also an active member and a past chair of SPE's Injection Molding Division.

Abstract

Powder bed fusion of plastics has reached a high maturity level up to now and the technology is used for different applications in the area of transport, consumer goods and for medical applications. Having a look at the area of energy storage systems mainly metal additive manufacturing techniques are used. The is an increasing need for innovative storage technologies, such as solid-state batteries, as well as novel production technologies. In this paper, a novel approach to manufacturing the so-called polymer separators for solid-state batteries with powder bed fusion is represented. Two different potential candidates for the polymer materials for the separator are analysed regarding their process behaviour in powder bed fusion. PEO and PVDF are commonly applied as materials for the solid-state separator. Optimal process parameters for the manufacturing of PVDF and PEO with powder bed fusion process to generate homogenous and dense layers are the key findings of this paper and provide deepened process understanding. As a result, the first proof of concept for producing separator layers by printing in a scalable process is shown.

About the Presenter

Prof. Wudys research area are laser-based additive manufacturing techniques with plastics and metals. The research focus is along the entire process chain from material development, new process strategies to automation solutions and quality management in additive manufacturing. Prof. Wudy studied plastics and rubber engineering at the University of Applied Science Würzburg-Schweinfurt and finishes her PhD at the Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) in the field of powder and beam based additive manufacturing in 2017. From 2015 to 2019, Prof. Wudy headed the "Additive Manufacturing" working group at the Institute of Polymer Technology and was Managing Director of the CRC 814 "Additive Manufacturing" at the FAU. In 2019, Prof. Wudy was appointed as Assistant Professor for laser-based Additive Manufacturing at the TUM.

Abstract

Injection moulding is an important manufacturing process in the fabrication of plastic parts. The repeatability of injection moulding machines has been an area of interest for several decades, to ensure the quality in the moulded product. It requires that each machine runs with multiple moulds and materials. The diversity of moulds and materials, require robust controllers that works well for different setpoints of speed and pressure. The tuning of machine controllers is a complicated task and should not be carried out each time a new mould or material is changed to ensure a consistent production flow. The injection moulding process is divided into several phases. The predominant moulding process in the industry is called secondary overpoint. It consists of a velocity-controlled fill phase and pressure controlled holding phase. The switchover between velocity control and pressure control of the injection cylinder is an important part of the cycle. It is important that the switchover occurs almost instantly to avoid overfilling the mould. It is desired to minimize the transient response of e.g. the pressure because a pressure drop before the holding pressure reference is achieved is undesired. A pressure drop results in reduction of the melt flow into the mould. This is undesired because the reduced flow will reduce the shear rate, hence increase the frozen layer making it harder or impossible to pack the elements. Previous research within bump-less transfer between the velocity-controlled phase and the pressure-controlled phase is based on making the pressure controller track the velocity controller. Hence ensuring continuity of the control input signal when the switchover occurs. A novel bump-less switch-over method is presented for hydraulic machines. The bump-less control switching approach is based on the control of flow into both chambers of the injection cylinder and is independent of plastic and mould properties. The controller structure is designed from a model-based approach. The controller is based on a cascaded controller structure, with a pressure and velocity controller. The bump-less transfer is secured through a continues reference generation and sharing of controller structure, making the switch-over less sensitive to mould and material parameters. It is possible to tune the time before the holding pressure is achieved through a single parameter, with direct relation to the settling time. The controllers and bump-less switch-over method are implemented on a rebuild commercial injection moulding machine. The results show in agreement with theory a bump-less fill to pack transition without any oscillations in the hydraulic pressure states. The controller structure enables bump-less switch-over between the velocity controller and pressure controller without the need for tuning when the mould and material is changed. If desired, it is furthermore possible to adjust the time it takes to reach the steady state holding pressure.

About the Presenter

Rasmus Aagaard Hertz received his M.Sc. in Electro Mechanical System Design from Aalborg University, Denmark, in 2017. With special interest in dynamic modelling and control of hydraulic systems. From 2017 to 2020 he has been working in industry with R&D Moulding, LEGO System A/S. Focusing on data and development of moulding platforms for the internal moulding factories. Since 2020 he has been an Industrial PhD student in cooperation with LEGO System A/S and Aalborg University, Denmark. Topics of interests include injection moulding, with focus on in-line material characterization, dynamic process modelling and control of the injection moulding process.

Abstract

Multi-materials plastic films are especially important in our daily food packaging. It can combine different polymers to achieve a range of properties, which can’t achieve by mono-material film. It can protect the food, increase the shelf life of packaged food, and reduce the food waste. However, the recycling of the multi-material packaging film faces big challenges due to the incompatibility of different materials. With the increasing awareness of plastic pollution issues, there is a clear and present need to find a way to recycle multi-material film structures to support the goals of the circular economy. Compatibilizer can help improve the compatibility of polar and non-polar components in the films by increasing the interfacial adhesion between the two phases. In the research, we developed a novel polyethylene (PE)/Polyamide (PA) or ethylene vinyl alcohol (EVOH) compatibilizer. Based on the tensile, dart impact and tear test results, with loading of this novel compatibilizer to the PA or EVOH at 1:10 ratio, up to 20% PA or EVOH can be incorporated into PE stream without scarifying too much mechanical properties and meet the Association of Plastic Recycler (APR) recognition requirements. The microscopy pictures clearly showed that the compatibilized blend has a homogeneous morphology while the blend without compatibilizer has clear 2 phases. This novel compatibilizer provides the possibility of recycle-ready multi-material film structure design and improve the sustainability of the multi-material films.

About the Presenter

MiaoMiao Xiao is a Research Scientist at Ingenia Polymers Corp., who is working on research and development of proprietary additive materbatches. She has a PhD degree in Chemical Engineering from University of New Brunswick, and holds a master’s in Polymer Processing Engineering and a bachelor’s in Polymer Material Science and Engineering from East China University of Science and Technology. She has a variety of research experience with polymer, including masterbatch development, polymer modification, polymer materials processing, reactive extrusion, and polymer synthesis.

Abstract

Accurate material characterization and appropriate modeling are essential for the prediction of the process behavior in injection molding simulations. The material viscosity is particularly important for the filling process and consequently for the process design. However, it must be taken into account that the viscosity of plastics depends, among other things, on the temperature, the shear rate and the prevailing pressure level. The influence of the pressure is often neglected due to the time-consuming characterization, even though existing models can include it. In the case of parts with long flow paths, thin-walled parts or materials with high filler content this can lead to an incorrect prediction of the pressure within the process, which can result, for instance, in an underestimation of the required filling pressure. In addition, incorrectly calculated pressures also lead to prediction deviations for the material density and thus affect the calculation of shrinkage and warpage of the component after cooling. Therefore, the aim is to characterize the pressure dependence of the melt viscosity and to investigate the modeling methodology for injection molding simulations. For this purpose, the pressure dependence of the viscosity for a polypropylene type 505P supplied by Sabic is determined using a modified injection molding rheometer by varying the shear rate and the temperature under near-production boundary conditions. To be able to change the absolute pressure level within the capillary, a throttle is used. For the characterization of the pressure dependence, the measurements are carried out with and without the throttle using the same machine settings. In addition, the viscosity is measured with a high-pressure capillary rheometer, which is a commonly used test method for creating material cards for injection molding simulations. The results show that the pressure dependence of the viscosity decreases with increasing shear rate. Using the generated experimental data, the calibration of the Carreau-WLF viscosity model is investigated in terms of modeling the pressure dependence of the viscosity. It is also shown that fits based on high-pressure capillary rheometer measurements are already affected by the influence of the pressure due to the measurement setup, since the characterization is carried out at higher pressure levels than assumed, even though the dependency is neglected in the modelling. Hence, for conventional fits the viscosity is slightly overestimated at high shear rates. Nevertheless, if the pressure dependence is included for the fitting, the viscosity can be accurately modeled within the investigated range.

About the Presenter

Education/Study: Steffen Verwaayen studied mechanical engineering at the RWTH Aachen University, Germany, specializing in plastics technology (Bachelor and Master). He wrote his master's thesis at Simcon kunststofftechnische Software GmbH in the field of injection molding simulation. Career path (2019 - present): Since September 2019, he is working as a research assistant at the Institute of Plastics Processing at RWTH Aachen University. He is employed in the Department of Structure Calculation and Materials Technology and leads the workgroup Material Modeling / CAE. Current research focus: Investigation of the pressure dependence of viscosity to improve injection molding simulation.

Abstract

Thermoplastic polyurethane (TPU) foams have a wide range of applications due to their high elasticity, good flexibility, low density, and high resistance to impact forces. They are used as cushioning for a variety of consumer and commercial products, including furniture, automotive interiors, helmets, and packaging. 3D printing of TPU foams would enable increased product design freedom and graded structures for novel and enhanced applications. To this end, unexpanded TPU filaments loaded with 0.0%, 7.5%, and 15.0wt.% thermally expandable microspheres (TEM) were prepared using a single screw extrusion system. TEM was incorporated using a masterbatch with 50wt.% ethylene-vinyl acetate carrier. The extrusion process parameters were set to achieve the lowest possible melt temperatures to prevent the foaming during filament fabrication. Foam samples were then in-situ printed using fused filament fabrication (FFF) process. 3-D printing parameters such as flow rate, print speed, and nozzle temperature were varied to achieve a wide range of foam density. Scanning electron microscopy and quasi-static compression tests were performed to characterize the cellular morphology and mechanical performance of the printed samples. Foams with good printability and dimensional accuracy were successfully achieved with densities as low as 0.15 g/cm3. The ability to 3-D print TPU foams with different densities provides higher design flexibility and allows to create more complex and optimized structures for a number of applications.

About the Presenter

Dr. Amir Ameli is a faculty member at the Plastics Engineering Department of the University of Massachusetts Lowell. He previously taught at Washington State University and has extensive experience with polymer foams and composites. His research focus is foaming, 3D printing, and injection molding, particularly for multifunctional and sustainable polymeric systems. He has published 65 journal articles, 115 conference papers, and several patents and book chapters.

Abstract

We developed a rheo-Raman spectroscopic system by combining a Raman spectroscope and rheometer to investigate the flow-induced crystallization behavior of polyethylene. Conformational changes that occurred during the flow-induced crystallization such as the formation of consecutive trans sequences or crystalline structure can be detected using Raman spectroscopy. We confirmed that no crystallization takes place at 130 ºC without shear flow because the fraction of the consecutive trans sequences and the crystalline structure was almost zero for 60 min. In the case of the flow-induced crystallization at 130 ºC with a shear flow of 100 s-1 for 30 s, the fraction of the long-consecutive trans sequences composed of more than 10 trans conformers increased with increasing time while the crystallinity was almost zero after applying the shear flow to the sample. Moreover, the long-consecutive trans sequences were formed as the precursor of the crystalline structure only at the shear rate with the Weisenberg number, which is the product of the shear rate and the Rouse relaxation time, greater than unity. These results suggest that the long-consecutive trans sequences are formed as precursors of the crystalline structure due to the stretching of the molecular chains under shear flow.

About the Presenter

• April 2019: Hiroshima University (Postdoctoral Fellowship of Japan Society for the Promotion of Science).
• January 2020: Nagoya University (Assistant Professor).
• March 2020: Japan Advanced Institute of Science and Technology (Assistant Professor)

Abstract

Global plastics recycling rates are low and the market share of recycled plastics is less than 10% at the moment. People are searching for different ways to further improving the recycle rates for plastics, especially for PET. However, companies’ sustainability efforts have been hampered because recycled PET (rPET) can exhibit poor mechanical properties compared to virgin PET (vPET) due to the lower intrinsic viscosity (IV). At Kaneka, we know additives can significantly improve the prospects for recycled plastics. The newly developed IV booster MV-01 showed promising performance when used in rPET. The study shows that at low dosing level MV-01 in rPET can improve the IV to the same level as vPET even after 4 passes. In addition, the mechanical property, transparency, YI, and Haze are all well maintained. Therefore the recycle content of PET can be significantly improved after adding MV-01 to the PET compounds.

About the Presenter

Technical leader with 10+ years of experience in product development of Engineering Thermoplastics. Proven track record of driving innovation with customer and market focus. Strong communication, team working and management skills vital for a dynamic global organization.

Abstract

Dimensional accuracy is, to this day, a challenging key quality aspect for manufactured parts using primary shaping processes. Many high-precision parts undergo multiple correction loops during the mold-making process to meet required geometric tolerances. Each iteration not only increases production costs, but also requires additional human and environmental resources. Dimensional inaccuracies are caused by the process-based part deformation, a superposition of the phenomena shrinkage and warpage. The mechanisms for shrinkage and warpage are strongly related to the dependence of a polymer's specific volume on pressure, and temperature (pvT-behavior). Shrinkage is inevitable since it is caused by the continuous decrease in melt temperature and the inherent crystallization process during solidification. Warpage results due to local and time-dependent variations of the melt temperature, cooling rate, and pressure and thus the local specific volume. These variations cause inner stress distributions that ultimately cause the part to warp. In order to reduce part warpage, the volumetric shrinkage must be homogenized across the part, which can be realized by manipulating the part's temperature locally and time-dependent. In this work, the warpage of a box-shaped geometry is aimed to be reduced by controlling the local temperature using dynamic heating elements. Dynamic temperature control is realized using a novel heating coating system based on plasma sprayed TiOx/Cr2O3, which is applied onto the cavity surface. Compared to conventional fluid-based temperature control systems, the heating coating system provides high heating rates of up to 25 K/s. Due to a coating thickness of 0.5 mm, the system is highly dynamic in its heating and cooling behavior. In order to ensure the feasibility of the heating coating system for complex geometries, a simulation-based procedure is presented, which identifies and compensates warpage-critical areas. In the first step, a commercial injection molding simulation software calculates part warpage while considering the water-cooling channel layout (reference). The resulting warpage file is exported to a 3D inspection software. Via a surface comparison between the CAD file (required drawing dimensions) and the warped geometry, the deviation was evaluated for all surfaces. A maximum warpage of 1.7 mm was measured for the box-shaped geometry and the polymer POM. This warpage is the reference value, which is used to determine the warpage reduction with the heating coating systems. Based on this initial calculation, multiple heating coating systems are modeled using CAD software. The modeled heating systems aim to homogenize thermal imbalances within the mold in such a way that the maximum part warpage is reduced by a factor of ten (compared to the reference). Each heating system is imported to the injection molding simulation software, where multiple power levels are applied during the molding simulation. The resulting warpage for each simulation is exported and evaluated. A significant warpage reduction has been achieved, with the maximum deviation being 0.35 mm (warpage reduction by factor five) with this procedure for the box-shaped geometry and the polymer POM. This work aims to achieve a maximum warpage of 0.17 mm, by optimizing the shape and applied power of the most suited heating coating system configuration. In the future, the modeled and simulated heating coating system will be validated in an experimental study.

About the Presenter

Technical leader with 10+ years of experience in product development of Engineering Thermoplastics. Proven track record of driving innovation with customer and market focus. Strong communication, team working and management skills vital for a dynamic global organization.

Abstract

The advent of additive manufacturing (AM) brought in new dimensions to the research and development efforts of cellular polymeric structures by offering design freedom, resulting in tailorable architected structures optimized for specific applications. This work proposes a two-dimensional (2D) density gradient approach to design graded honeycomb structures for energy absorption applications. Graded honeycomb structures having three levels of density gradients (low, medium, and high) and their uniform density honeycomb equivalents were manufactured using material extrusion (MatEx) based fused filament fabrication (FFF) AM process. The material used for the FFF process was thermoplastic polyurethane (TPU) elastomer (Polyflex). The relative density of the structures was in the range of 0.259 – 0.346. A comparative study of the compressive behavior of the graded and regular honeycomb structures was carried out using in-plane quasi-static compression tests. Unlike regular honeycomb structures, all the graded honeycombs showed gradual stepwise deformation. Compared to their honeycomb equivalent counterparts, the high gradient honeycomb showed significantly different force-displacement profile compared to medium and low gradient honeycombs. While high gradient honeycomb showed higher maximum crushing force compared to the honeycomb equivalent, medium and low gradient honeycombs showed higher crush force efficiency. The experimental results were evaluated and compared with non-linear finite element analysis (FEA) simulation results. The hyperelastic properties of the TPU material were defined using Mooney-Rivlin constitutive model. The simulation results agreed well with the experimental results. The proposed 2D gradient parametric design methodology, coupled with the experimental and simulation results, can broaden the knowledgebase of graded honeycomb design principles, thus providing unique opportunities to develop and improve additively manufactured light-weight structures for commercial applications, ranging from automotive and transportation to healthcare and consumer products.

About the Presenter

Dr. Mohammad Faisal Ahmed is an Assistant Professor in the Department of Industrial and Engineering Technology of Southeastern Louisiana University, who has interdisciplinary expertise in industrial, manufacturing, mechanical, and materials engineering. Dr. Ahmed published 12 journal articles in refereed journals such as Materials and Design, Additive Manufacturing, Journal of Applied Polymer science, Materials Chemistry and Physics, Journal of Mechanical Behavior of Biomedical Materials, and Micromachines among others. Dr. Ahmed’s research interests are additive manufacturing, sustainable manufacturing, architected materials, in-space manufacturing, industry 4.0, smart materials, and polymer processing. He is a member of SPE, IISE, and SME. He is devoted to teaching and training future engineering and technology graduates through his research activities to foster inclusive higher education and contribute to the economic development of the State of Louisiana. He is very active in STEM education and outreach activities. Apart from serving as an advisory member (e.g., MakerSpace Committee - LaSTEM Network, FIRST Robotics Mentoring Campaign etc.), he conducts outreach activities for K-12 students and teachers (e.g., Print the Future Camp funded by Louisiana Materials Design Alliance (LAMDA) – NSF & Louisiana Board of Regents).

Abstract

Current electrification market needs materials with good balance of Flow, Flame Property and Mechanical Performance. In this talk, we will discuss the rheological features of three commercially available linear, branched and hyper-branched polycarbonates (PCs) using comprehensive investigations. Applications of rheological properties to enhance Z-strength in Large Format Additive Manufacturing (LFAM) will also be discussed. Additionally, high temperature extensional Rheometer (CaBER) was used to understand the evolution of microstructure at high temperatures. The experiments were performed at temperatures ranging from T = 250 to 370°C to a maximum Hencky strain of ten. At lower end of the temperature range, no significant degradation of the linear and branched Polycarbonate (PC) was observed either in the shear or extensional measurements. Beyond, T > 300°C branched PC showed a dramatic increase in extensional viscosity which helps in Flame performance (anti-drip) better than its linear counterpart.

About the Presenter

Dr. Manojkumar Chellamuthu has 14 years of research and engineering experience in structure-process-property relationships of complex fluids. An R&D Rheology Leader at Sabic Specialties with Strong Technical Skills Who Drives Innovation and New Product Development in the Areas of Structure-Property and Property-Processing Relationships. His technical work on developing industry-first High Temperature Extensional Rheometer has led to understand the evolution of microstructure for anti-drip properties at temperatures relevant to UL-94 V Flame testing. Dr. Chellamuthu has 15+ patents awarded/pending for innovations in engineering thermoplastics. Dr. Chellamuthu has received a best paper award by Applied Rheology division for using "Rheology as a Tool to Understand Anti-drip Properties in Flame Retardant Polycarbonate Resins" Manojkumar received his Ph.D. from the University of Massachusetts, Amherst. He Joined Sabic after spending 2 years as a post-doctoral scientist at NIST, Polymer Division

Abstract

The single-screw extruder is one of the most important plastics processing machines. In order to improve the design of the machines and in order to predict relevant process variables, computer-aided approaches as three-dimensional simulation are increasingly coming to the fore. Depending on the process zone, different modeling approaches are used. For the feed zone, the so-called Discrete Element Method (DEM) is becoming increasingly important. For the melting zone, Computational Fluid Dynamics (CFD) is predominantly used with sub methods like the Finite Volume Method (FVM). However, to date, no method has been explored that allows joint consideration of the feed zone and the melting zone. In this paper, building on the authors' recent work, a novel approach is presented that allows a joint consideration of these zones. The approach explored is based - for the first time in the case of the single-screw extruder - on a coupled CFD-DEM method. The approach pursued represents a three-phase model. It is based on the Volume of Fluid (VoF) Method and couples it with DEM. In this work, the melting process in the single-screw extruder is simulated using the new approach with joint consideration of the feed zone and the melting zone. To calculate the melting process, a melting model recently published by the authors is used. The results are compared with experimental investigations.

About the Presenter

• Born in Germany in year 1991
• studied Mechanical Engineering (Dipl.-Ing.) at TU Kaiserslautern, Germany
• started working as a phd-student at Institut für Kunststofftechnik, University of Stuttgart beginning 08/2017
• Current Position: Head of Plastics Processing at IKT.

Abstract

Since the invention of LEGO System in Play (The more bricks you have, the more you can build.) in 1955, LEGO ensures its play experience by providing high precision interlocking LEGO elements. To keep our Planet Promise, LEGO aims to make bricks from more sustainable sources without compromising on quality or safety. This requires exploring a wider range of materials. This presentation aims to show the main technical consideration to secure the quality of LEGO bricks regardless of material and process variations. In the injection moulding process, many factors such as resin, colours, suppliers and element design could impact the element properties. In this presentation, a Design of Experiment (DoE) was carried out to study the influence of processing parameters on shrinkage and mechanical properties. Besides, the influence of colours on shrinkage and crystallinity was also investigated.

About the Presenter

Wendi Wang is moulding technology specialist at the LEGO group in Denmark. With a background in polymer physics, she is interested in understanding the link between process variables and material properties through a scientific data-drive approach. Co-presenter: Kelly Briceno is a Materials Engineer and have been working for more than 15 years with different materials across Europe. Since 2019, she has been dedicated to research, understanding and supporting the implementation of more sustainable materials in the LEGO portfolio.

Kelly Briceño is a Materials Engineer and have been working for more than 15 years with different materials across Europe. Since 2019, she has been dedicated to research, understanding and supporting the implementation of more sustainable materials in the LEGO portfolio.

Abstract

Based on its mouldless, layer-wise manufacturing principle, screw-extrusion-based Additive Manufacturing (AM) allows for the efficient and economical production of thermoplastic prototype parts. During manufacturing, thermoplastic pellets are molten in a single-screw extruder and discharged through a nozzle. As the extruder is moved by a kinematic, the melt is subsequently locally discharged in a strand- and layer wise fashion to successively build up a part, similar to established AM processes such as the Fused Filament Fabrication (FFF). In contrast to FFF, standard thermoplastic pellets can be processed, as a single-screw extruder instead of a heated nozzle is used for plasticising the material. Thus, enabling injection moulding (IM) prototypes to be manufactured from series IM grade materials, including filled materials such as talc-filled polypropylene. However, the layer-wise additive manufacturing leads to anisotropic mechanical part properties in terms of strength and stiffness, which differ from the properties of the final IM-part, currently limiting the use of AM-parts to concept- and geometric-prototypes. These properties not only result from lower part strength orthogonal to the direction of deposition due to incomplete healing between adjacent strands, but also from a difference in filler-orientations, based on the process specific flow behaviour of the melt during processing. To extend the use of parts manufactured in screw extrusion AM to functional- or even technical prototypes, for which the mechanical properties are crucial, an understanding of these differences in the anisotropic mechanical behaviour of AM- and IM-parts is necessary. In the scope of this work, the quasi-static tensile and flexural properties as well as the high-speed tensile properties of additively, screw-extrusion-based manufactured and injection moulded parts are investigated, taking into consideration differences in the filler orientation between the manufacturing processes. To account for the anisotropy, testing is performed in several directions relative to the direction of deposition in AM or the direction of flow in IM. Furthermore, optical investigations are performed to assess the impact of filler orientations. The investigations are performed by manufacturing 1BA tensile test specimens from a 20 wt.% talc filled IM grade polypropylene material in screw-based AM and IM, which are subsequently used to perform quasi-static tensile and high-speed tensile testing. In addition, test specimens in accordance with DIN EN ISO 178 are manufactured for flexural testing. To allow for comparability, the test specimens are indirectly manufactured, i.e. both in AM as well as IM plate geometries are produced, from which the test specimens are milled. The AM parts are tested parallel and orthogonal to the strand-direction as well as at an angle of 30° and 60° relative to the strands. For IM, testing is carried out parallel and orthogonal to the direction of flow. In addition, µCT and microscopic investigations are conducted to analyse the orientation of the filler. While the results show an anisotropy in strength and stiffness for both IM and AM specimens, the anisotropy of these properties is significantly more pronounced in case of AM. This is based on the higher degree of filler orientation in the strands of the AM-parts. At the same time, only a partial orientation of the fillers in flow direction can be determined for IM-parts, showing that the fillers used can impact the comparability of AM and IM-prototypes. Additionally, it is shown that a higher comparability of the part properties is possible in the case of a quasi static load, compared to high-speeds of load application, limiting the use of AM-prototypes to such load cases.

About the Presenter

After successfully studying mechanical engineering at RWTH Aachen University, Johannes Austermann completed his master's studies at the University of Wisconsin - Madison and RWTH Aachen University with distinction in the field of plastics engineering. Since 2019, he has headed the "Additive Manufacturing" working group as a graduate research assistant at the IKV. The focus of his work is on the process- and material-related properties of additively manufactured components.

Abstract

The effect of applied shear flow and pressure on the miscibility and structure for the binary blends of bisphenol-A polycarbonate (PC) and low-molecular-weight poly(methyl methacrylate) (PMMA) was studied using a conventional capillary rheometer. The lower critical solution temperatures (LCSTs) of PC/PMMA (70/30) and PC/PMMA (80/20) were found to be 260 and 270°C, respectively, without flow field under atmospheric pressure. During capillary extrusion at/below 250°C, however, shear induced demixing was detected. Moreover, pressure induced demixing was also detected at high pressure. Finally, surface segregation of PMMA fraction was observed without phase separation for PC/PMMA (90/10).

About the Presenter

• 1989 Tosoh Corp.
• 2005 Japan Advanced Institute of Science and Technology

Abstract

Accumulated used polymers and tires cause several ecosystem issues in landfills. A practical method was proposed to reuse recycled polyethylene terephthalate (rPET) and ground tire rubber (GTR) powder by melt composite process. A composite material was developed in this work using GTR for reinforcement and rPET for matrix. The effect of two non-reactive (styrene-butadiene-styrene (SBS) and styrene-ethylene-butadiene-styrene (SEBS)) and three reactive (ethylene-methyl acrylate-glycidyl methacrylate (EMA-GMA), ethylene-glycidyl methacrylate (EGMA) and SEBS grafted with maleic anhydride (SEBS-g-MA) coupling agents on the mechanical properties of the composite material were evaluated. Mechanical tensile and impact strength properties were evaluated to determine how coupling agents affect composite behavior. All reactive coupling agents improve the mechanical behavior of composite materials, whereas non-reactive ones have little effect. EMA-GMA and EGMA are more reactive with rPET than SEBS-g-MA. Using 10 wt% of EMA-GMA in the composite of rPET/GTR (4:1) increases the tensile strain and impact strength (950% and 23%, respectively) and decreases maximum tensile strength and Young's modulus (16% and 35%, respectively).

About the Presenter

Aboulfazl Barati is a researcher with 18 years of experience in researching and teaching. He has been taught many chemical and polymer engineering courses at BSc, MSc, and Ph.D. levels. He has an international reputation for research on chemical and polymer engineering, especially polymer processing and polymerization. He has published over 70 journal papers in high-quality peer-reviewed journals, of which 5 of his papers are ground-breaking in their field. Also, he has published more than 80 conference papers and has been invited as a keynote speaker to many of them. His research has widespread applications in many areas of polymer and chemical engineering, for example in polymer processing, polymer blending, biomedical product, environmental applications, and the agricultural industry. Currently, he is a researcher at the Center for Materials and Manufacturing Sciences (CMMS) in Troy University. He is working amongst American and international individuals.

Abstract

The macro-issues the plastics industry is trying to resolve today pertain to sustainability, supply chain shortages, and the lack of skilled labor. Within the injection molding sector, manufacturers typically perform a full validation when a mold is moved to a different injection molding machine (IMM) or there is a material change. These full validations are labor-intensive, expensive, and not sustainable. Moreover, these methods may or may not utilize scientific molding principles. There has been a demand for a standard "part process" development method to transfer a mold between IMMs that is more efficient and can embrace variation in resins. iMFLUX's Auto-Viscosity Adjust (AVA) technology has made doing so easier with its low, constant pressure injection molding process. This adaptive technology enables the molding process to automatically adjust parameters in real-time around parts' response. This research focuses on developing a regenerative part process with low, constant pressure that is independent of resin and machine. Using AVA and cavity pressure sensors, two molds' processes were transferred to another capable press with the original process, no user adjustments, and parts were studied for visual and dimensional integrity. It was determined that iMFLUX can automatically regenerate optimized part processes in different IMMs deemed capable with negligible part variation as seen from the visual and dimensional results. This is the first time an intelligent controller can autonomously redevelop and validate a part process to mold parts within spec despite varying IMMs and resins.

About the Presenter

Lexington Peterson is a field process engineer at iMFLUX, a wholly-owned subsidiary of Procter & Gamble in Hamilton, Ohio. She is an alumni of Pittsburg State University where she graduated with a B.S. in Plastics Engineering Technology as well as a B.S. in Polymer Chemistry. Lexington has been an active member of the Society of Plastics Engineers for 5 years. Her passion for plastics is sustainability-focused, which happens to be one of iMFLUX's main initiatives. Brandon Birchmeier is the Technology & Innovation Director for iMFLUX with nearly 20 years of hands-on injection molding experience varying from large automotive applications to high-speed packaging. He is a graduate of Ferris State University, and has been at iMFLUX for 8 years. Brandon is a driving force at iMFLUX with a passion for developing autonomous molding intelligence, sharing the benefits of the iMFLUX technology, and changing the way the world molds.

Abstract

Polymer material extrusion additive manufacturing processes like fused filament fabrication (FFF) are increasingly being used for structural applications. Accordingly, there is a growing need for computational modeling to characterize and predict the process output and printed part performance under load. Prior studies have shown that the modulus and strength in the build direction (Z-direction) are sensitive to the surface bead shapes and can vary extensively depending on the print settings used. This presents a challenge for part-level (macro-scale) finite element analysis (FEA) because the material properties required for such models can vary from part to part or even different locations within the same part. The use of stress concentration factors is a critical step in computing effective material properties to be used in macro-scale numerical models. However, theoretical stress concentration factors (kt) published in literature for material extrusion AM are limited to tensile loading only. In this work, we demonstrate how the kt from tensile loading can be extended to other load cases. Meso-scale FEA was used to perform parametric studies with varying bead shapes. The models were subjected to pure bending loads as well as bending loads combined with shear loads. The stress concentrations were then evaluated, but with multiple iterations of the wall thickness used for nominal stress calculations. The results were compared to the results from pure tensile loading, and it was observed that the choice of wall thickness is trivial for tensile loads but is critical for bending loads. An equation for effective wall thickness was derived that yields consistent stress concentration factors for any bead shape, irrespective of the applied load. The results were also compared with the effective wall thickness for calculating the Z-direction modulus as published in literature. Ultimately, separate recommendations for effective wall thickness are presented for calculating modulus, strength, and the actual geometry used in macro-scale FEA models.

About the Presenter

Sarat Kundurthi is a PhD student at Michigan State University currently working on computational modeling of polymer additive manufacturing processes. He holds Bachelors and Masters degrees in Mechanical Engineering from the Indian Institute of Technology, Madras. He also has 4 years of industry experience at Eaton Corp., with expertise in finite element modeling.

Abstract

High-density polyethylene (HDPE) exhibits poor melt strength which limits its widespread application especially where it is exposed to an elongational deformation flow in processes such as film blowing, melt spinning, and foaming. In this study, by taking advantage of in-situ nanofibrillation of thermoplastic polyester ether elastomer (TPEE) in HDPE matrix, we improved the rheological properties as well as the foamability of HDPE. TPEE consists of a hard crystalline segment of polybutylene terephthalate (PBT) and a soft amorphous segment of polyether. The polarity of these two groups causes TPEE to be thermodynamically incompatible with non-polar HDPE. Therefore, styrene/ethylene-butylene/styrene copolymer grafted maleic anhydride (SEBS-g-MA) as a compatibilizer was used for reducing the interfacial tension between two blend components. In the first step, a 10% masterbatch of HDPE/TPEE with and without compatibilizer was prepared employing a twin screw extruder. Next, to fabricate fiber-in-fiber composites, the 10% masterbatch was diluted and processed by spunbonding. Scanning electron microscopy (SEM) revealed that not only the spherical size of HDPE/TPEE decreased significantly after SEBS-g-Ma inclusion, but also a much smaller TPEE nanofiber size (60-70nm for 5%TPEE) was achieved. Moreover, the extensional rheological results showed strain-hardening behavior for both compatibilized and non-compatibilized stretched samples at earlier times, at a given extensional rate, compared to the unstretched counterparts. It is worth mentioning that the improvement of extensional rheological properties was more pronounced for compatibilized samples compared to the non-compatibilized ones. This can be attributed to smaller nanofiber size and consequently higher aspect ratio as well as a more robust 3D fibrillated network. Finally, batch foaming was conducted to investigate the foamability of fibrillated nanocomposites.

About the Presenter

Professor Chul Park received his Ph.D. from MIT in 1993. He is Distinguished Professor of Microcellular Engineered Plastics at University of Toronto. He has an international recognition in polymer foam area. He has published more than 1500 papers, including 500 journal papers and four books with 27,500 Scopus Citations and 89 Scopus H-index. Prof Park serves as Editor-in-Chief for Journal of Cellular Plastics. He has been inducted as an Academician Fellow into 6 academies including the Academy of Sciences of the Royal Society of Canada, the Korean Academy of Science and Technology, and the Chinese Academy of Engineering. He is also a Fellow of 6 other professional societies including the Society of Plastics Engineers.

Abstract

Multi-layer materials (e.g. in packaging or technical parts) are used to achieve certain properties of products. However, a major challenge of plastics recycling is the separation of the various polymer layers. One example for this are airbags. Airbags consist primarily of polyamide 6.6 fibers and an additional silicone coating. To prepare for recycling, the wastes are processed to easily dosable fabric particles. However, the fabric particles subsequently do not consist exclusively of PA66, but still contain the silicone coating. In principle, it is possible to process these PA66 silicone fabric particles into plastic granules by extrusion, though this results in a product of low quality. This is mainly due to the low adhesion between the PA66 matrix and the contained silicone particles. The low adhesion leads to increased interfacial delamination and thus to premature failure. Mechanical properties such as impact strength or elongation at break are therefore very poor and high-quality technical components cannot be manufactured from this recyclate. An alternative to the extrusion of silicone-contaminated PA66 waste is the chemical separation of the silicone from the polyamide. However, the disadvantages of this recycling alternative are the large amounts of solvents required as well as the high energy requirements. Up to now, there is no efficient process for the mechanical recycling of PA66 wastes which contain silicone. However, from an environmental point of view and due to the large available amount of this type of waste (e.g. airbags), it would be desirable to process it into a high-quality recyclate which can be applied in the production of technical plastic components. Therefore, the aim of this work was to investigate a new approach for the recycling of PA66/silicone wastes using the example of airbag wastes. Thereby, the silicone particles should not be regarded as impurities but as a functional additive/impact modifier. To this purpose, a coupling between the PA66 matrix and the silicone particles was formed through a reactive extrusion in a twin-screw extruder by means of a silane coupling agent. This type of modification intents to reduce the risk of interfacial detachment in the resulting recyclate. After the reactive extrusion, an in-depth material analysis was conducted to verify the achieved coupling reaction in the twin-screw extruder. Rheological tests confirmed the formation of a cross-linked structure through the addition of the coupling agent. However, it cannot be determined through the rheological analysis if a chemical bonding has taken place. It can be assumed that the silicone has become inert during the airbag production and therefore none or only few functional groups are available. However, silanes and silicones have a basic structural similarity. Therefore, physical bonding can be expected, which may well lead to improved mechanical performance. The improved integration of the silicone particles into the PA66 and the reduction of cavities in the compound could be demonstrated by using Nano-IR-AFM analyses. Additionally, mechanical tests showed the increase in notched impact strength and elongation at break and therefore the possible function of the silicone as an impact modifier. The reactive extrusion process was further investigated in a hinged twin-screw extruder. After stopping the process, it is possible to open the processing unit and to take samples at different positions along the processing zone. This further analysis of the process emphasized the need for an adjustment of the machine parameters as well as the screw concept in order to optimize the reaction conditions in the processing zone and to prevent post-reactions as well as degradation effects. Future experiments will concentrate on the detailed investigation of the exact nature of the formed bonds (physical and/or chemical). In this context, the formation with additional silane types should also be taken into account. Furthermore, the process parameters of the reactive extrusion will be optimized with the aim to increase the additive content in order to further increase the notch impact strength while avoiding process-related post reactions that could hinder the processing of the compounds.

About the Presenter

Studies: Material Sciences (M.Sc.), University of Gättingen, Germany. Career: since 2017, scientist at the Institut für Kunststofftechnik (IKT), University of Stuttgart (Germany). Field of research: material engineering, (reactive) compounding, polyamides, biopolymers

Abstract

In an attempt to attest and justify that a polymeric medical device as possibly affected by some polymer process change(s) of device manufacturing would be substantially equivalent to relevant legally-marketed counterpart in view of its biological safety and functional effectiveness, a practical approach for statistically evaluating inherent thermo-chemical stability of polymer, namely activation energy of thermal degradation that is closely dependent of the underlying thermal history of device manufacturing, is proposed in compliance to relevant regulations and industrial guidelines. Accordingly, a series of thermo-gravimetric analysis (TGA) experiments can be comparatively conducted per ASTM E1641 standard practice and then kinetically studied to determine the measured activation-energy means for some "test" polymer samples taken from affected device, compared to some "control" polymer samples taken from relevant legally-marketed device, using the so-called Ozawa-Flynn-Wall analytical method. The statistical equivalence or superiority of affected device, compared to legally-marketed device, can be then technically assessed by performing the pertinent two-sample heteroscedastic t-test on any statistical differences in the so-measured activation-energy means between the affected and "control" polymer samples.

About the Presenter

Xiaoping Guo is currently a Senior Associate Research Fellow at the R&D Science & Technology, Abbott Laboratories (Electrophysiology Division), St. Paul, Minnesota. As a polymer specialist, he provides relevant technical services on Polymer Engineering & Science in support of product designs, advanced process development, post-market product analysis, and biological assessment of medical devices, and etc., across various medical device divisions in Abbott. He also conducts innovative polymer material development with specialty applications in novel medical devices, and performs a variety of in vitro and in vivo biostability studies of medical polymers for medical devices. Dr. Guo obtained his Ph.D. degree in Polymer Engineering from the College of Polymer Science & Polymer Engineering, The University of Akron, Ohio, in 1999.

Abstract

Large-scale additive manufacturing (AM) often produces parts with unintended deformation and failures during the manufacturing process. The process involves a hot molten polymer deposited on a previously deposited and cooled solidified layer, generating a temperature mismatch between the layers. The temperature difference causes thermal contraction mismatches with the different shrinkage rates, generating thermal residual stress between layers. Due to the residual stress, printed structures experience warpage and delamination. Therefore, understanding the heat distribution behavior essential to predict undesired failures. We used biomaterial reinforcement which has been widely used thanks to its sustainability, specific stiffness, and low cost compared with carbon and glass reinforcement. The reinforcement increases the structural stability of the printed part, reducing deformation. However, the challenges of unexpected deformation remain in the utilization of natural fiber reinforcement in the AM process. The goal of this work is to investigate the effect of internal structures (a.k.a., infill patterns) on heat distribution and deformation in the large-scale additive manufacturing system with wood fiber-reinforced polylactic acid. A sequentially coupled thermal-structural analysis was conducted to predict the temperature field and warpage with thermo-mechanical properties, which were measured by a thermo-mechanical analysis test and a dynamic mechanical analysis test. We printed a box geometry model with three different infill geometries. During the process, temperature data were gathered with an IR camera, and final deformations were measured. The simulation model was verified with the experiments, and the results show a good agreement between predicted and measured temperature profiles and deformations. We applied the developed simulation model to a roof tray with complex geometries for a case study.

About the Presenter

Dr. Seokpum (Pum) Kim is an R&D scientist at Oak Ridge National Laboratory (ORNL), specifically in the Manufacturing Demonstration Facility. Pum's expertise is in digital manufacturing with polymer composites, specifically focusing on material processing and design optimization through computational analysis and predictions. Pum received his Ph.D. in mechanical engineering at Georgia Tech in 2016 and joined ORNL after his Ph.D program. He has developed multiple algorithms related to additive manufacturing and optimization methods for design and processing, which led to 27 publications (h index of 17) and 7 patents currently in pending.

Abstract

Whereas much is known about the complex viscosity of polymeric liquids, far less is understood about the behaviour of this material function when macromolecules are confined. By confined, we mean that the gap along the velocity gradient is small enough to reorient the polymers. We examine classical analytical solutions [Park and Fuller, JNNFM, 18, 111 (1985)] for a confined rigid dumbbell suspension in small-amplitude oscillatory shear flow. We test these analytical solutions against the measured effects of confinement on both parts of the complex viscosity of a carbopol suspension and three polystyrene solutions.

About the Presenter

Steacy Coombs is a second year PhD candidate in Dr. Giacomin's Polymers Research Group at Queen's University in Kingston, Ontario Canada. My research in my accelerated master's degree at Queen's University explored the connection between macromolecular structure and melt elasticity, but this work is silent on extrudability. Specifically, She explored how macromolecular branching affects melt elasticity, with a special focus on melt complex viscosity (storage and loss moduli). For her PhD thesis, she aims to delve into how confinement affects the rheological properties of polymer solutions and design a microfluidic concentrator.

Abstract

Thermoplastic vulcanizates (TPVs) are high-performance polymeric materials, classified as thermoplastic elastomers, and contain a continuous thermoplastic matrix with crosslinked elastomers as a dispersed phase in their structure. TPVs combine the high elasticity of crosslinked elastomers and the easy processability and recyclability of thermoplastics. For this reason, TPVs are nowadays used in automotive, white goods, electronics, etc. as more 'green' materials than crosslinked conventional elastomer products. The most widely produced TPV type is polypropylene (PP)/ethylene propylene diene monomer (EPDM), which is the focus of this study. The dynamic vulcanization (DV) technique is applied in the production of TPVs. DV is a complex reactive compounding technique. The crosslinking reaction takes place industrially with peroxides in PP/EPDM system. However, it is known that during dynamic curing with peroxide, side reactions such as undesired chain scission and undesired disproportionation reactions occur especially in PP phase. For this reason, coagents are used together with peroxides to increase the efficiency of crosslinking. In this study, polyhedral oligomeric silsesquioxane nanoparticles, containing reactive side groups, were used as coagents for PP/EPDM system for the first time in the literature. The peroxide crosslinked PP/EPDM/A-POSS system was dynamically vulcanized in a lab-scale microcompounder (Xplore Instruments, The Netherlands). Mechanical properties of samples were determined by tensile, hardness and compression set analyses. Scanning electron microscope (SEM) and atomic force microscope (AFM) were used to evaluate the phase morphology. The results showed that nano-reinforced network structure improved the performance of the TPV materials.

About the Presenter

Prof. Dr. Guralp Ozkoc was born in 1979 in Sinop, Turkey. He received his B.Sc. degree from Gazi University and his M.Sc. and Ph.D. (2007) degrees from the Polymer Science and Technology Department of Middle East Technical University (ODTU) in Ankara, Turkey. During his Ph.D. study, he researched as an intern-PhD at DSM in 2005 in The Netherlands. His Ph.D. thesis was on the "processing and characterization of short glass fiber and nanoclay reinforced ABS/PA6 blends". He also focused on the dispersion characteristics of nanoclays and polymer phases of ABS and PA6 concerning microcompounding conditions. After his Ph.D. graduation, he started as an Assistant Professor at Kocaeli University (KOU), Department of Chemical Engineering, in 2007. He founded the Plastics and Rubber Technology Research Group in 2008 at KOU, where 50+ MSc and Ph.D. students are actively conducting research. He supervised more than 35 M.Sc. and 15 Ph.D. theses in the last ten years. Furthermore, he chaired the Polymer Science and Technology Graduate Program for seven years, from 2011 to 2018. In 2019, he was promoted to a full-professorship position at Kocaeli University. In September 2020, he moved to The Netherlands to research additive manufacturing of polymer composites at TNO-Brightlands Material Center as a senior researcher. After working in this position for one year, he departed to Xplore Instruments BV/The Netherlands as Chief Technology Officer and General Manager. In 2021, Dr. Ozkoc started as a contract professor at Istinye University Department of Chemistry. He holds six patents and is the author of many international scientific papers and proceedings. Dr. Guralp Ozkoc's research interests are polymer compounding, polymer blending, composites and nanocomposites, elastomeric/rubber compounds, and biodegradable and biomedical materials.

Abstract

Polyvinyl butyral (PVB) is used in laminated glass to bind multiple glass layers. Key applications of laminated glass include safety glasses in architectural and automotive. Even if glass breaks, adhesive nature of PVB keep pieces of glasses together preventing human injury and damage to the surrounding. Because of this aspect of PVB, its used in automotive windshield applications. Each car windshield contains ~ 1kg of PVB. At the end of car life, glass in windshield is separated from PVB and recycled. In this study the PVB removed from glass was evaluated for its feasibility to recycle. Specifically, rigidity and indentation properties of PVB were studied. Substantial improvement in these properties was achieved by adding acrylic additives to PVB, making it suitable for applications such flooring. It was found that hardness of PVB was increased by addition of acrylic additives, resulting in improved indentation and rigidity. Glass transition temperature of PVB was increased by > 10°C. Significant increase in storage modulus was also observed. Effect of acrylic additives on tensile and impact properties are also presented. Being adhesive in nature, PVB tends to stick to metal surfaces making it difficult to melt process, addition of acrylic additive improved handling of PVB during melt processing preventing it from sticking to metal surfaces. Modification of PVB with acrylic enabled recycling of PVB in various applications, specifically flooring. With improved indentation and rigidity performance, use of PVB in flooring can be increased significantly. PVB modification can diverge >100,000 lbs. of PVB from land fill and can be used in value added applications. Acrylic modification showed potential to recycle PVB into useful applications making complete recycling of windshield possible, leading to overall improvement in automotive recycling.

About the Presenter

Dr. Manoj Nerkar is Global Application Technology Leader at Dow Chemicals. He received Ph.D. in Polymers at Queen’s University, Canada. He has ~ 18 years of experience in polymer industry. His expertise include polymer blends, composites, polymer processing and polymer structure-property relationship. Prior to joining Dow, Dr. Nerkar worked at GE Plastics, Solvay and TerraVerdae BioWorks. His current research focus at Dow includes acrylic additives, core shell impact modifiers, PVC, Polycarbonate blends and epoxy.

Abstract

Cobalt-60 gamma radiation is the most commonly used form of ionizing radiation for sterilizing polymer-based medical devices. However, recently it has been challenged by growing shortages in cobalt-60 supply and throughput, and in its security threat as a radioactive source. Non-isotope-based methods including electron beam (e-beam) and X-ray represent potential alternatives to gamma radiation. However, prior to practical implementation, devices and polymers sterilized by these alternative techniques must be thoroughly characterized from several perspectives, including in their potential detrimental effects on mechanical properties. To this end, this talk will present our recent experimental studies that compare mechanical properties of medical devices sterilized with gamma radiation to those sterilized with e-beam or X-ray at sterilization relevant doses. Specifically, the talk will explore these effects in three prototypical commercial devices that contain approximately ten distinct polymers commonly used in medical device industry (high-density polyethylene, polycarbonate copolymer, polybutylene terephthalate, high impact polystyrene, polyvinyl chloride, acrylonitrile butadiene styrene, styrene-butadiene copolymer, polyethylene terephthalate, vinyl-methyl-silicone, acrylonitrile butadiene rubber). Taken overall, our results suggest that neither e-beam nor X-ray adversely alter the mechanical properties of the devices or polymers relative to that of gamma irradiation, thus paving the way for medical device manufacturers to transition from gamma radiation to e-beam or X-ray sterilization of polymeric medical devices.

About the Presenter

Dr. Md Kamrul Hasan is a Post Doc Research Associate at Pacific Northwest National Lab (PNNL). He received his PhD in Mechanical Engineering from Texas A&M University and his master's from Hokkaido University, Japan in the field of Mechanics of Materials. His research work focuses on the mechanical characterization of the irradiated polymers in medical applications.

Abstract

The melting of a plastic filament in an FFF extruder is characterized by the fact that there is hardly any frictional heating, and instead heat conduction and radiation between the nozzle wall and the filament plays the major role. Experiments have shown that these heat transfer mechanisms limit material heating and thus the overall production rate. For this reason, many efforts have been made to capture the melting behavior of the filament through analytical models, numerical simulations or experiments. This presentation focuses on a CFD simulation of non-Newtonian and non-isothermal polymer flow through the nozzle of a fused filament fabrication printer. The simulations were performed for a wide range of filament velocities at different nozzle temperatures and then compared with two different types of experiments. A comparison with experimentally measurements of the force required to push the filament through the nozzle showed that the assumptions used for the simulations are suitable to predict the melting and flow behavior in the relevant processing range. In addition, an experimental method was used to allow in-situ observation of melt flow in a printing nozzle using X-ray micro-computed tomography. In this way, it was possible to study the velocity distribution in the nozzle and to gain insights into the melting mechanism that can be used for future modeling approaches.

About the Presenter

- In 2018, graduated in mechanical engineering at the University of Erlangen-Nuremberg with a stay abroad at the University of Wisconsin-Madison. - Since the end of 2018, PhD student at the University of Stuttgart with research focus on modeling and simu

Abstract

Many years ago, Union Carbide Corporation (UCC) had established a well-equipped melt rheology lab designed to accomplish large-scale melt testing to simulate high shear conditions and small-scale dynamic and steady shear capabilities to both predict low deformation phenomena and delineate key features of molecular structure. UCC later initiated an aggressive metallocene catalyst development program to develop polyethylenes (PEs) with unique molecular structures. In an effort to fully characterize the key features of molecular structure that was manifested in the observed viscoelastic properties, we calculated the melt relaxation spectra for the new PEs and in comparing them to incumbent PEs, we found the new PEs to be differentiated. This led to a family of patent applications to protect the technology, and a new parameter, called the "relaxation spectrum index" or "RSI" to quantify the breath of the relaxation time distribution reflecting the novel molecular structures. The RSI proved to be a useful parameter to use to not only delineate interesting features of molecular structure, but also to predict large-scale processing behavior, such as motor load and amperage in extrusion of layers and components for wire and cable applications. This presentation will illustrate the power found in calculating and characterizing the relaxation spectrum with dynamic oscillatory shear experiments. As an illustration, a case study will be presented in which a new compound was to be developed for high-speed thin-walled chemical-foamed telecommunications wire insulation. Many key rheological phenomena needed to be simultaneously considered to design the next-generation product, and the RSI proved to be instrumental in allowing the necessary differentiation between inventive and comparative materials. This led to the development of a powerful set of patent claims to protect the strategic space for UCC (now Dow). The power of this rheology-based approach to intellectual property is that the invention is not limited to a particular composition — instead, the patent claims would be a potential challenge to any composition that meets the critical rheological profile.

About the Presenter

Dr. Scott Wasserman is R&D Technology Leader/Intellectual Capital Manager in Dow's Packaging & Specialty Plastics segment, a responsibility that includes the Wire & Cable and Adhesive businesses and Dow's digital innovation. He has functional responsibility for intellectual assets, including patents, agreements and licensing opportunities, and additional experience with numerous complex divestiture projects. Concurrently, Dr. Wasserman has served for 12 years as Adjunct Professor of Chemical and Biomolecular Engineering at his alma mater, the University of Delaware, teaching Rheology & Viscoelasticity and Plastics Sustainability in a course on Polymer Science. He earned his Ph.D. in Chemical Engineering from Princeton University in 1993 and his Bachelor of Chemical Engineering degree with Distinction from the University of Delaware in 1988. Dr. Wasserman started with Union Carbide Corporation in 1994 and approaches a combined 29 years with Dow. He has been active with the International Wire & Cable Symposium organization for many years, serving currently as Chair of its Board of Directors. Dr. Wasserman also serves as Chair of the Scientific Advisor Board for EFRC Center for Plastics Innovation and on the External Advisory Board for MRSEC Center for the Center for Hybrid Active Response Materials, both housed at the University of Delaware. He is also a member of both the Society of Rheology and the Society of Plastics Engineers (SPE). Dr. Wasserman has 10 granted US patents and most recently was the corresponding author of the chapter "Wire and Cable Applications of Polyethylene" in the SPE-sponsored Handbook of Industrial Polyethylene and Technology, published by Scrivener Publishing LLC in 2017.

Abstract

In this study, we introduce the concept of in-situ nanofibrillation as an efficient, low-cost, and environmentally friendly tailored technique for the enhancement of polycarbonate (PC) properties. PC/ Ethylene Propylene Diene Monomer Rubber (EPDM)-fibril composites are prepared by a twin-screw extruder. Taking advantage of the crosslinked rubber phase as well as nanofibrillation processing play the main role in properties improvement. Modifications of the mechanical and rheological properties of PC via fiber-spinning of PC/EPDM are distinguished by elongation and crosslinked network of the second phase (EPDM) properly in the main matrix (PC). Morphological observations showed the well-dispersed fibrillar phase of EPDM with a high aspect ratio in the PC matrix. PC with nanofibrillated EPDM also improved the mechanical properties, especially the ductility and the toughness, while increasing the stiffness, in comparison with neat PC. The change in the tensile, Izod Impact and flexural properties was governed by the draw ratio. Hence, having stretched fibrils is an effective way to enhance the mechanical and rheological properties. Rheological investigations proved that PC with nanofibrillated EPDM has dramatically improved melt elasticity compared with neat PC. Linear viscoelastic behavior of small amplitude oscillatory shear measurements showed a strain-hardening, solid-like, behavior in the fiber-spun PC/EPDM, which was not observed in the neat PC or the melt-blended PC/EPDM.

About the Presenter

Hamidreza is a current Ph.D. candidate in Mechanical Engineering under the supervision of Prof. Chul Park at the University of Toronto. He is currently studying and researching the manufacturing and characterization of various simple and reactive blends as well as hybrid composites and foams containing polymeric nanofiber inclusions. To present his research and get feedback from academic and industrial visions, he attended many conferences as a presenter and speaker. He also published several papers as a main author or co-authors in high-impact journals. According to his beliefs in practically engaging academic research and studies with the industries, he worked and was involved in many company projects such as Sabic, Hanwha, TOTAL, etc. during his Ph.D. degree. Nowadays, he is a founder and director of one of the successful holding companies in Canada which are working in several fields; from the construction of buildings, importing and exporting polymeric productions, researching polymer science, investing in polymeric materials for constructions, etc. Hamidreza attempts to get involved and collaborate with all of you in novel ideas in polymer science for the improvement of people's facilities, lifestyles, and environmental protection.

Abstract

Electric vehicles have garnered a lot of interest and sales of these EVs are growing with many companies around the world producing them and entering the market besides Tesla. This presentation will cover changes in polymer usage in EVs compared to conventional internal combustion engine vehicles (ICVs). It will include: Very interesting and unbelievable history of electric vehicles, Plastics, elastomers, composites and other materials for light-weighting, hanges in polymer materials and design needed for the several differences between the requirements of ICVs and battery electric vehicles (BEVs) and what factors led to these changes, Use of recycled materials and sustainability, Challenges BEVs faced, and how innovation overcame those challenges, and Other challenges that remain and need more innovative approaches.

About the Presenter

Ashok M. Adur has a Ph.D. in Polymer Science & Engineering and trained in Executive Entrepreneurship. He has over 45 years of success in R & D, business development, marketing and general management at several chemical, plastics and paper companies, which ranged from a startup to those with multi-billion dollars in revenue. He has been honored as a Fellow of the Society of Plastics Engineers (SPE). As a consultant at Everest International Consulting (LLC). Dr. Adur has expertise in plastics, polymers, elastomers, composites, microencapsulation & specialty products. He is considered an expert in polymer compounding and plastics recycling, particularly in compatibilization of multi-component systems and developing strategies for intellectual property issues in polymers and plastics. His wide experience covers most polymers and processes for end markets including packaging, automotive, appliance, wire & cable, medical device, building materials, material handling, fragrance, consumer products, plastics compounding and other industries. He has published 85 papers in professional journals and presentations at professional conferences and filed 77 patent applications, resulting in business of over $2.5 billion/year. He has recently written 3 chapters for a book on Bio-Products to be published in early 2023, based on his experience in bioplastics, recycling and sustainability.

Abstract

The chemical and physical effects of ionizing radiation on polymeric materials is reviewed with a primary focus on radiation sterilization of disposable medical device materials.

About the Presenter

Director and Subject Matter Expert of Materials at Fresenius Kabi Fenwal for 13 years; Senior Research Scientist at Baxter Healthcare for 17 years, Technical Lead for Baxter Healthcare Conversion of Products to Radiation Sterilization in the early 1980s; Senior Research Scientist at Viskase Corporation for 7 years; Project Leader at ITW for 5 years; Author of 20+ technical publications with 22 US patents.

Abstract

The overall objective of this project is to conduct applied research that leads to an innovative agile manufacturing plant for onsite fabrication of recycled thermoplastic products at US military forward operating bases (FOBs). These plants need to designed so they are entirely self-contained in 20-foot ISO containers for both shipment and operation. A study by the US Department of Defense (DoD) of base camp waste confirmed that the single largest source of waste plastics is Polyethylene Terephthalate (PET) from water and other beverage bottles. This project to convert reclaimed PET (rPET) to useful products was initiated by the DoD's Strategic Environmental Research and Development Program (SERDP) in 2018 with Emc2 as the lead along with the US Army Corps of Engineers and is in its final year of completion. Earlier results from this on-going effort have been presented at the other conferences including the Society of Plastics Engineers' Annual Technical Conferences (ANTEC®) Additive Manufacturing (AM) sessions in 2020 and 2022. This paper describes a recent significant breakthrough in the above research to convert rPET flakes (in granulate form) obtained from water bottles directly into final finished product — thus eliminating the need to compound the flakes into pellets and then extruding filament prior to AM. This state-of-the-art AM technology has been developed jointly by Emc2 and re:3D using their Gigabot-X printer originally designed to use pellets or flake. These printers could replace traditional manufacturing methods, especially in remote environments, low-resource settings, or places with limited access to supply chains such as FOBs. re:3D's Screw based Fused Granulate Fabrication (FGF) addresses these challenges by 3D printing directly from rPET flakes. In this work, the modifications to the Gigabot-X printer along with the experimental and analytical efforts involved are described in detail so as to enable the use of granulated rPET flake in AM. Thermal properties, extrusion consistency, and mechano-structural properties are characterized and optimized. Example models with value in the FOB ecosystem were identified and printed from the rPET granulate to demonstrate the ability to convert locally generated waste into value-added objects via AM.

About the Presenter

Dr. Krishnaswamy received his Ph.D. in Mechanical Engineering from the University of Washington, Seattle, WA. Prior to co-founding Emc2 in 1998, he was a Senior Scientist at Battelle Memorial Institute in the Advanced Materials Department. He has conducted extensive research in both analyti-cal and experimental areas of engineering mechanics and is a renowned expert in the mechanical and failure behavior of plastics, composites, and bio-based materials, especially in structural -bearing applications. He has led both the technology development and worldwide standards activities in the area of recycled plastics and composite lumber and has been the Principal Investigator of the DOD's SERDP Project to convert recycled thermoplastics into useful products at Forward Operating Bases . Dr. Krishnaswamy has co-authored over 80 publication in technical journals, conference proceedings and has given numerous invited talks at academic and research institutions. He the holds 6 patents.

Abstract

At high shear rates and strains in the start-up of simple shear of polyethylene, polymer melts go through a catastrophic and non-uniform cohesive failure that happens throughout the material which is called melt rupture. The melt rupture behaviour of a bimodal molecular weight distribution polyethylene is investigated under simple shear through visual and time-to-rupture analysis. Under constant stress, melt rupture is known to be a time-dependent phenomenon and time-to-rupture is a parameter to quantify the durability of polymer melts. The durability of polymer melts is industrially important since it defines the highest flow rate (production rate) possible in processing methods like extrusion. However, studying durability in extrusion is challenging for two reasons: 1. Confounding effects of pressure and shear rate gradients in the capillary. 2. The effect of the negative pressure formation at the edge of the die. The simple shear studies make it possible to study the material's response to the flow conditions by eliminating the mentioned effects. The characteristics of wall-slip are believed to be related to many instabilities in capillary and simple shear flows such as die drool, sharkskin and melt rupture. The relationships though are not yet fully understood due to the complexity of the process and the number of important parameters. In this study, we investigate the relation between slip and the time-to-rupture of a bimodal molecular weight distribution polyethylene using a sliding plate rheometer (SPR). The SPR tests were conducted at 190°C for 6 different nominal shear rates and the stress is recorded (under slip condition). The no-slip behaviour is measured using a stress-controlled rotational rheometer by conducting small amplitude oscillatory shear (SAOS) tests at 190 °C assuming the Cox-Merz relationship. The slip at constant stress is calculated from the difference between the true shear rate (no-slip condition obtained from SAOS results) and the nominal shear rate in SPR (slip condition). During the start-up of simple shear of polyethylene, three main phenomena can happen: simple shear, adhesive or cohesive failure near the wall (slip) and melt rupture. Once the material ruptures, the stress plateau ends, and the stress drops to zero. The time-to-rupture is defined as the time between the start of the experiment and the end of the stress plateau in stress transient curves. To further investigate the slip and melt rupture, the stationary plate in the SPR setup was replaced with a glass plate and the flow recorded using a camera. A glass plate is a good replacement for steel as it is also a high-energy surface. The visual studies were conducted for four resins with different molecular weight distributions. It was verified that the materials go through melt rupture after first slipping. The time-to-rupture analysis has been conducted on the material with the highest content of short chains. The other materials resist melt rupture within our experimental window in time. The results show that there is a negative power law relation between the nominal shear rate and the time-to-rapture of the material. The relation between time to rupture and stress changes with slip regime. Moving from weak to strong slip, there is a shift in the time-to-rupture curve to shorter times and lower stress.

About the Presenter

Dr. Paula Wood-Adams is the Special Advisor on Innovation at Concordia University in Montreal, Canada. She is a professor of Chemical and Materials Engineering and was formerly the Dean of Graduate Studies and the Interim Vice-President of Research and Graduate Studies. She is well known for her work on the rheology, slip, and crystallization of polymers and their relationships with molecular and micro-structure. As an academic leader, she has provided strategic and operational direction to various functions of research and graduate studies at Concordia for the past 12 years. She has been an active member of provincial and federal funding agency peer-review committees including, the New Frontiers Research Fund of the Tri-agency Institutional Programs Secretariat, the National Sciences and Engineering Council of Canada (NSERC) and the Fonds de recherche du Québec (FRQ). She has published 75 journal articles on her research in materials science and has received over $3.7M in research grants. Dr. Wood-Adams is the chair of the board of governors of the National Cybersecurity Consortium, former vice-chair of the board of governors for John Abbott College and former President of ADÉSAQ, the Quebec association of deans of graduate studies.

Abstract

Short fiber reinforced thermoplastic parts subjected to mechanical and cyclic loading during a long period of time eventually fail. To prevent premature failure in service, predictability is key when designing load bearing components. The lifetime depends obviously on the nature of the thermoplastic material but also on the amount of reinforcement, the type of reinforcement and the set-up of the injection process. All these ingredients make the fatigue modeling of short fiber reinforced plastic parts highly challenging. Dedicated solutions at several stages of the modeling workflow are thus required. The ingredients needed are (a) an accurate material model for any orientation tensors and any loadings, (b) a reverse engineering procedure allowing to identify the model parameters from a reduced set of experimental data in order to reproduce the measured lifetime at specimen level, (c) efficient structural and fatigue solvers enabling to predict life-time for various type of loading conditions (constant amplitude, random signal, frequency/time domain loadings, …) and (d) an overall methodology able to account for stress gradients so to deliver accurate predictions for any part geometry and mesh. In this paper, an ICME (Integrated Computational Material Engineering) solution is presented, leading to accurate predictions of the fatigue life of short fiber reinforced parts for any type of experimental signal. The framework combines engineering tools that enable design engineers to predict fatigue life of engineering plastics applications, including material anisotropy and nonlinear behavior. This paper highlights the key features of the framework and demonstrates its ability to predict the response of a representative demonstration part.

About the Presenter

TBA

Abstract

Blister packs is one of the most important presentations in the pharmaceutical industry. As we all know, the brand owners and the global market are being pushed by the sustainability trends and regulations to look for alternatives towards recyclability. Typical structures of blister packs contain not friendly materials like PVC, PVDC OR PCTFE. This conference will present some test of structures using EVOH and COC creating a blister packaging with high barrier and excellent optical properties that also are design for mechanical recycling.

About the Presenter

Diana Maya holds a B.S. in Chemical Engineering from the Universidad Nacional de Colombia and two Master's degrees from the Universidad de los Andes in Colombia. One of them is a Master's in Mechanical Engineering focused on Polymers Processing and the second Master's degree is in Environmental Engineering. For her Master's degree thesis in Mechanical Engineering, Ms. Maya received the National Golden Recycler Award in 2006 in the Research Category bestowed by the Environmental and Territorial Ministry of Colombia. She has about 20 years of work experience in various aspects of the plastics industry globally spanning polymerization, extrusion of raw materials in processes like blown film, cast, thermoforming and tenter frame to the experience in brand owners giving in general a particular focus in her career on high barrier packaging. For the past nine years Eng. Maya has worked with Kuraray - EVAL® as a Technical Service and Development Engineer for the Americas and was recently promoted to Senior TS&D Engineer (Engineer III). Her experience also includes one published patent, multiple patent applications and several publications in Specialized Plastic & Food magazines. In her current roll in Kuraray America, Inc. she is also responsible for R&D projects heavily involved in Sustainability challenges.

Abstract

A targeted energy input in the melting zone, which is sufficient to plasticize the material without damaging it, is one of the main goals of compounding on co-rotating twin screw extruders. High temperatures damage the material just as much as extreme shear, caused by high rotational speeds, does. Fast melting sometimes leads to overstressing the material, which is why a gentle melting zone is preferred. But gentle melting means a longer melting zone and therefor longer extruders, which need more space and energy. This conflict leads to the need of a model to predict the exact energy input for one single element in the current process to find a compromise between both factors. The specific energy input can be described as power per mass flow, where in turn power can be simplified to torque and speed of the extruder. At present, no models are available to describe the torque along the extruder with sufficient accuracy. In the present paper a new approach will be carried out, to calculate the determination of energy input by calculating the resistance of the plastic against the screws, causing a torsion of the screws. This can be repatriated to the torque and therefor the energy input. Different zones along the axis of the extruder are distinguished and described with different models. This results in a global model for the breakdown of the torque along the extruder. Basically, the flow of the individual zones is considered and the force of the melt flow on the screw surface is determined.

About the Presenter

Laura started studying mechanical engineering at the Paderborn University in 2013. She focused her studies on plastics technology. Subsequently, She also completed a Master's degree at Paderborn University and further specialized in plastics technology. She wrote her Master's thesis on "Carbon Fiber Length Degradation Along the Twin-Screw Extruder" at KTP, where she then became a research assistant in the compounding department.

Abstract

A key objective of process simulation of thermoplastic injection molding is the accurate prediction of the final part shape. Deviation of the molded part shape from the intended design is known as warpage. In this research, we present a method to improve the accuracy of warpage prediction by using calibrated material properties. The calibrated material properties can be the modulus, Poisson’s Ratio and Coefficient of Thermal Expansion. The calibration is achieved using a database of measured shrinkage molding data from a series of standardized test plaque having a variety of molding thicknesses and using a variety of process condition settings (packing pressure, melt temperature and injection velocity). Unique in this approach is that the calibration of material properties is performed on-line at the time of the process simulation rather than in an off-line calibration process which prepares static material property values. The advantage of on-line calibration is that the calibration can be based on the particular molded test cases from the database of measured shrinkage data which are most relevant for the part design and process to be simulated. For example, the material property calibration can be done using measured shrinkage samples for which the plaque thickness and process parameters most closely match the thickness and indented processing conditions of the part to be simulated. In this way, the calibration of material properties is uniquely adapted for the design which is to be simulated. Presented in this work are comparisons to actual molding data of final part shape predictions for both unfilled polymers and fiber reinforced polymer composites performed both with and without the shrinkage test calibrated material properties. This includes a thin-walled part for which a post-molding buckling response is correctly predicted when the calibrated material properties are used.

About the Presenter

Dr. Franco Costa is Research Director for the Autodesk® Fusion Injection Molding group. Over 30 years with Autodesk Moldflow® he has contributed to the technologies of 3-dimensional flow simulations, thermal analysis, crystallization analysis, structural analysis, final net part shape prediction and multi-physics for the plastic injection molding simulation industry. Franco leads the Moldflow Solver Research and Development team.

Abstract

The fatigue performance of unidirectional fiber-reinforced plastics is subjected to complex damage mechanisms, dependency on the load direction, and strain-dependent material behavior. In addition, the strength of the fiber/matrix interface is one of the main influential factors on the composites’ fatigue life. Its characterization, however, is effortful and the results are prone to large scatter. Moreover, the microstructure within the composite leads to a complex stress-strain field that changes with each fiber break, or detachment. So far, this resulting internal stress-strain fields have only been possible to be investigated by numerical approaches. In this work, a single fiber detachment model is extended to a representative volume element model (RVE) within the finite element method. A composite material made of carbon fibers and epoxy resin is being investigated. The behavior of the two constituents is assumed to be orthotropic and isotropic elastic, respectively. The complex microstructure is represented by a random fiber distribution generated with a sequential expansion algorithm, and periodic boundary conditions are applied. The fiber strength is modeled as a Weibull-distribution. A parameter study is carried out to analyze the influence of the fiber/matrix detachment rate on the internal stress distribution. Principal Component Analysis (PCA) is introduced to reduce the dimensionality of the problem. The obtained results show that PCA can reduce successfully complex stress-strain fields to an eigenvalue and eigenvector problem. Furthermore, the simulations show that the fiber detachment length correlates with the number of load cycles.

About the Presenter

Bachelor degree in mechanical engineer at the National University of Colombia. Master degree in Simulation Sciences at the RWTH-Aachen. Currently, research assistant and PhD. candidate at the Institute for Plastic Processing at the RWTH (IKV). Research experience in computational mechanics of fiber reinforced plastic and fatigue.

Abstract

Environmental sustainability is one of the pillars of the PepsiCo Positive agenda and packaging is a significant component of our Carbon footprint as well as single use plastics use. Use of biopolymers in Flexible packaging could help reduce the green-house gas emissions associated with food packaging. In addition to that, flexible packaging has also a challenge from an end of life point of view as the current multi-material structures are not recycle friendly in existing infrastructure. We have developed a multi-pronged approach to address this problem globally by developing materials which are bio-based and can be recycled or easily composted. This is based on a deep materials science understanding of novel materials development with the right partners, solving engineering challenges of conversion and building supply chain that is committed to leaving a more sustainable world for our future generations.

About the Presenter

Dr. Sri Narayan-Sarathy is Technical Director of Sustainable Packaging and Senior Research Fellow at PepsiCo. Sri received her M.Sc. in Chemistry and M.Tech. in Polymer Science & Technology from Indian Institutes of Chennai and Delhi respectively. She got her Ph.D. in Polymer Science & Engineering from the University of Massachusetts at Amherst. Prior to joining PepsiCo in 2010, Sri was Technology Manager/Principal Scientist at Ashland Performance Materials. Sri’s research interests are in the areas of Materials Science and Chemistry. At PepsiCo, she is leveraging her extensive experience with different polymer chemistries to identify and develop bio-based materials for sustainable flexible packaging with good end of life. She has several patents and publications to her credit. Sri also has an adjunct faculty appointment in the Department of Grain Sciences at Kansas State University and sits on the board of Biodegradable Products Institute (BPI).

Abstract

Tandem foam sheet extrusion is a complex process that requires optimization to produce quality sheet at high rates. The goal of this presentation is to describe the process, show how rates can be increased, and provide case studies.

About the Presenter

Dr. Mark Spalding is a Fellow in Dow Plastics in Midland, Michigan. He joined Dow in 1985 after completing a BS degree from The University of Toledo and a MS and Ph.D. from Purdue University, all in Chemical Engineering.

Mark has held technical positions in Corporate R&D, Polystyrene R&D, Plastics R&D, and INCLOSIA* Solutions. He authored over 170 technical publications. His expertise is in single-screw extrusion and related polymer processing technologies. He co-authored a book with Professor Gregory A. Campbell with the title "Analysis and Troubleshooting of Single-Screw Extruders.

He has solved some of the most complicated extrusion problems at Dow customer’s plants by developing and applying sophisticated troubleshooting methods. He has designed extrusion systems for most of Dow’s major customers for virtually every resin that Dow produces. He is a Fellow and an Honored Service Member of the Society of Plastics Engineers.

Abstract

Injection molding simulation began in the 1970s, and has advanced in sophistication to the present day. Material testing technology has also evolved over the same time period, to meet the increased demands of simulation. The accuracy of injection moulding simulation is influenced by many factors such as modeling of part geometry, runner and nozzle, mesh type and density, mathematical finite element solution and process settings. The focus of this paper is material data, from the latest material testing methodologies, outlinings the evolution of material testing technology to meet the demands of the highest accuracy simulation. Investment in state of the art equipment and continued involvement in research ensures advancement towards future goals to: reduce environmental impact and provide sustainability data, expand the materials database, and improving accuracy. Testing methods for the viscous, thermal, visco-mechanical, thermo-mechanical and mechanical properties are outlined and discussed. This paper outlines the background behind the development of latest test methodologies, with a focus on in-line rheological methods, pressure-volume temperure measurement, thermal conductivity, specific heat, linear coefficent of thermal expanasion and non-linear mechancial methods.

About the Presenter

Dr. Russell Speight joined Moldflow, Australia in 1995 (acquired by Autodesk in 2009) and has held roles of increasing responsibility within the Engineering Simulation Team. He is currently Director, Manufacturing Simulation, managing a global engineering team. Russell was awarded a Ph.D. in 1993, University of Bradford, UK and an M.B.A. in 2018, Deakin University, Australia. Previously, engaged as President of the Australia New Zealand SPE Section, Vice-President, and SPE Councillor for six years. Fellow of the Society of Plastics Engineers. Chartered Engineer and Fellow of Institute of Measurement and Control. Inventor of Patented Automated Machine Optimization Technology, with over 70 research publications. He holds the position of Honorary Visiting Professor of Polymer Process Measurement Technology, University of Bradford, UK, Advanced Materials Engineering.

Abstract

Copper glass ceramic (CGC) particles have been incorporated into a variety of thermoplastic polymers (e.g. nylon, TPU, PVC) via melt compounding to impart antibacterial and antiviral properties to the polymer. Experiments with these CGC thermoplastic composites showed that they effectively killed more than 99.9% of bacteria and viruses on the surface within 2 hours. Antimicrobial (AM) activity was not impacted by the presence of pigments (e.g. carbon black) and was maintained for at least 1 year when the parts were stored under ambient conditions. Key to enabling and maintaining bioactivity was the addition of booster molecules with the CGC particles to enhance the AM activity for plastics where the CGC particles alone result in low initial and/or long-term AM efficacy. Copper leach rates from the polymer composites were measured using UV-vis spectroscopy and ion chromatography methods to understand the impact of leachability on AM activity. These polymer composites are suitable for various downstream processing such as injection, blow, and compression molding. Moreover, long-lasting AM efficacy in CGC thermoplastic composites can be achieved without methods that require modifying the bulk plastics for intentional metal coordination.

About the Presenter

Dr. Tony Frutos is a Technology Director in the Emerging Innovations Development group at Corning Incorporated. He has over 23 years of new product development experience. Tony has been issued 19 U.S. patents, and is an author on more than 39 technical publications. He holds a bachelor's degree in chemistry from Brigham Young University and a Ph.D. in analytical chemistry from the University of Wisconsin, Madison.

Abstract

Single-use bags have been banned or restricted around the world. Substitute alternatives have been explored, including biodegradable bags, reusable bags and the use of other materials such as paper or cotton. The Life Cycle Assessment (LCA) is the most widely accepted tool for carrying out comparative studies between alternatives. In this study, the literature on LCA of grocery bags was reviewed in search of common conclusions. In general, reusable plastic bags are identified as the alternative with the lowest environmental impact , obtaining on average a 73% reduction in the climate change index compared to the alternative with the highest impact in each analysis. Reuse and recycling have a lower environmental impact than composting, landfilling or incinerating. Open challenges are discussed, including the requirement for the development of a new index to quantify plastic leakage into the environment.

About the Presenter

Director of Technical Progams at SPE since october 2022. Technical Director of the Plastic and Rubber Research Institue in Colombia for 12 years. He worked at the Polymer Engineering Center at the University of Wisconsin-Madison as a research and teaching assistant. Production Engineer from EAFIT University with a PhD from the University of Wisconsin-Madison. Researcher, teacher and consultant in areas of knowledge that include polymer processing, sustainability and circular economy in plastics, modeling and simulation of transport phenomena, packaging engineering, rheology, among others.

Abstract

Injection molding and extrusion are the two basic processing methods in plastics technology. The most likely applications, especially in case of extrusion, are in the packaging sector. Here, polyolefins represent the most important type of plastic in terms of volume. Worldwide, the total consumption of polyolefins is estimated at over 150 million tons per year. However, during the extrusion of polyolefins such as polyethylene or polypropylene, flow instabilities can occur as soon as the mass flow exceeds a critical value. These instabilities mainly show up in three different forms. They are referred to as the "sharkskin effect", the "stick-slip effect" and the "gross melt fracture". The effects mentioned appear with increasing shear rate. In the case of the sharkskin effect, periodic tearing of the product surface result, producing a sharkskin-like structure. The occurrence of the stick-slip effect manifests itself in products (for example, strands or films) with alternately smooth and jagged structures. If even higher shear rates during the process lead to melt fracture, in which the product undergoes extremely severe deformation. The flow instabilities can limit the production rate and thus also affect cost efficiency. To counteract them, processing aids such as fluoropolymers are added in practice. Fluoropolymers are considered to be extremely environmentally critical. Due to the strong C-F bond, these polymers can stay in the environment for an extremely long time and are therefore considered persistent. Due to this persistence, the introduction of the substances into the environment is so to say irreversible and poses a serious risk to humans and the environment. For this reason, their ban is often called for. In the past, various alternatives have been developed as polymer processing aids. Most of them are based on siloxanes. However, siloxanes also have high stabilities and durabilities, which is why they might be harmful to the environment, as well. The aim of this study therefore was to develop a novel and highly effective processing aid master batch that does neither pose a risk to health nor the environment. The new developed master batch should suppress flow instabilities and thus shift the process towards higher mass throughputs. In order to investigate the effectiveness of the processing aid master batches developed, they were tested with a high-pressure capillary rheometer. The capillary rheometer offers to detect the resulting pressure fluctuations, which are caused by the flow instabilities. For this purpose, a novel and high-resolution measuring nozzle was developed. This nozzle allows complete characterization and high-precision testing of the efficiency of the developed master batches. Various additives were tested. It was shown that the measuring method is suitable for detecting and accurately analyzing flow instabilities in the nozzle. It was also found that polysorbate is suitable as a flow aid for polyolefin extrusion. By adding polysorbate, the pressure instabilities could be suppressed so that surface effects were no longer visible.

About the Presenter

• since 02/2018 IKT - Institut für Kunststofftechnik (University of Stuttgart, Germany) Research Associate, Material Engineering Research projects in the fields of plastic pollution, biopolymers and sustainability, polymer porcessing
• 04/2014 – 09/2017 IKT — Institut für Kunststofftechnik (University of Stuttgart, Germany) - Master Thesis at the Institut für Kunststofftechnik IKT, University Stuttgart Title: "Analysis of the Processing Behavior of Recycled Carbon Fibers by Means of Direct Fiber Compounding in the Injection Molding Process". - Research Assistant: research areas include materials engineering, biopolymers, plastics and environment - Student Assistant: research areas include materials engineering, biopolymers, plastics and environment - Bachelor Thesis at the Institut für Kunststofftechnik IKT, University Stuttgart Title: "Mechanical Characterization of Thermoplastic Starch - Blends".
• 04/2016 – 04/2017 — Dr. Ing. h.c. F. Porsche AG (Weissach, Germany) Internship and Student Trainee in the field of materials engineering - pre-development and technology management

Education

• 11/2014 – 11/2017 — University of Stuttgart (Stuttgart, Germany) Master of Science, Technology Management
• 09/2010 – 10/2014 University of Stuttgart (Stuttgart, Germany) Bachelor of Science, Technology Management
• 09/2001 – 09/2010 Hegel-Gymnasium Stuttgart - Vaihingen (Stuttgart, Germany) Abitur

Abstract

The currently achievable flow path lengths in injection moulding often represent a limitation for thin-walled packaging applications as well as for technical components with long flow paths respectively high aspect ratios. Previous investigations have shown qualitatively that a micro-structured mould surface can positively influence the flow and cooling behaviour of the plastic melt in the cavity. This can be attributed to micro air cushions between the plastic melt and the mould, which influence the heat transfer from the plastic melt to the cavity. A lower required injection pressure or the realisation of longer flow paths are the result. In addition, faster filling times at constant injection pressures can reduce the cycle time of the injection moulding process. In order to investigate the influence of the surface structure in more detail, comprehensive practical and simulative investigations are carried out on the resulting flow path length, the surface replication and the melt temperature. Initially, different mould surface structures were produced using sink electrical discharge machining (SEDM) and then analysed with regard to the surface properties such as the surface roughness Ra and the material properties in the surface layer. The influence of the process parameters injection pressure, melt and mould temperature as well as two different polypropylene moulding compounds on the achievable flow path length for the different mould surfaces was then investigated and compared with an unstructured mould cavity. For this purpose, a flow meander tool with an aspect ratio of 460.5 was used and the parameters were varied in a full factorial test design. In addition, the influence of the mentioned parameters as well as the influence of the flow path on the structure replication is examined using laser-scanning microscopy and the melt temperature and cavity pressure along the flow path are determined by means of pressure and infrared sensors. So far, up to 4 % higher flow paths could be achieved due to the SEDM generated mould surface. At the same time, a significant dependence of the surface impression on the flow path length and thus also on the local melt properties such as the pressure or the temperature is shown. In addition to the practical test series, simulative investigations are carried out. By adjusting the heat transfer coefficient as a function of the structure replication in the simulation of the injection moulding process, the influence of the mould structuring on the cooling of the plastic melt can be taken into account. Using the pressure and temperature data of the mould sensor system as input and calibration data as well as the findings from a macroscopic simulation of the modified surface, a micro-model of the surface will also be developed and simulated. The boundary layer of the injection mould, which is influenced by the SEDM process, with e.g. a changed thermal conductivity, can also be taken into account. Finally, the results on the influence of the surface structure on the heat transfer will be transferred into commercial simulation software in order to improve the design of injection moulds.

About the Presenter

Professional Career

• (since 07/2021) — He heads the Injection Moulding Department at the IKV and is in responsible for the organisation, guidance and supervision of 15 scientific staff members.

Education/Studies

• (10/2010 to 07/2016) — Christoph Zimmermann studied mechanical engineering at the Rheinisch-Westf-lische Technische Hochschule Aachen, specialising in plastics technology (Bachelor and Master). He wrote his master's thesis at the Institute for Plastic Processing (IKV) at RWTH Aachen University in the field of elastomer design. Doctorate
• (08/2016 to 06/2021) — Following his studies, he worked as a research assistant at the IKV. In the department of moulded part design and material technology he worked on the modelling the mechanical material behaviour of thermoplastic elastomers under complex stress conditions.

Abstract

Reinforcements are a key component of TPO's, enabling formulators to achieve the modulus targets required for a broad range of applications, while brightness can be a challenge. Trinity has developed a new Altibright pyrophyllite mineral that is a high brightness, high aspect ratio reinforcement and is domestically mined and produced in North America. This presentation will provide an in-depth comparative study of physical performance of this new product in both polypropylene homopolymers and copolymer formulations.

About the Presenter

With over 25 years of experience in the mining and industrial minerals industry, Mr. Hurley's business development initiatives have spanned 14 countries. Mr. Hurley has had a successful track record of developing businesses from concept through research and development and into commercial production. Mr. Hurley holds a BSc., Chemistry from Memorial University.

Abstract

It is well known that melt processing post-consumer (PCR) or post-industrial (PIR) recycled resins can generate foul odors due to contamination and/or thermal degradation. Additional components, such as printing inks and adhesives in plastic packaging, may be viewed as contaminates in the recycled resin and can contribute to this problem. Some of these odors could be from volatile organic compounds, VOC’s, with known safety concerns. With a growing need in the flexible packaging industry to increase circularity through the use of PCR and PIR materials, there comes an increase in risk for health concerns and food safety. Amcor has developed methods using gas chromatography, GC, along with heated headspace sampling, HS, to chemically identify and measure the VOC released from PCR/PIR that have known safety concerns such as acrolein, methyl acrolein, and benzene. These methods help Amcor evaluate the quality of PCR/PIR sources to determine feasibility for certain applications, and aid in the design of next-generation recycle ready packaging films. This will be a discussion on the development of the testing methods along with results of VOC analysis.

About the Presenter

Kevin Guigley, PhD has spent most of his career in the development of products and analytical methods of polymeric materials and supporting chemistries. Kevin had obtained his doctorate in material science and engineering specializing in polymer science from The Pennsylvania State University. He also obtained a master's in chemistry from University of Illinois at Urbana-Champaign. With his background in both polymer science and chemistry, most of his technical efforts focused on the chemistries that affect the material properties of polymers and the resulting products. Kevin is a proven product developer as evidenced by authoring or coauthoring 5 patents and 7 patent applications. Kevin's initial work at Owens Corning was improving and developing the coatings on fiberglass, i.e. sizing chemistry, to improve mechanical and cyclic fatigue properties of fiberglass reinforced composites. His work at Owens Corning included developing and optimizing the properties of fiberglass composites in the applications of filament wound piping, thermoplastic composites, wood plastic composites, sheet molding compounds, fiberglass insulation, and ballistic composite armor plate. At Amcor, Kevin is continuing his interests in the chemistry of polymer materials by developing analytical methods for measuring the physical and chemical contaminants in recycled resins. This presentation will discuss his efforts on developing GC methods to measure and identify chemical contaminates with low to moderate boiling points, a.k.a. volatile organic components, VOC's.

Abstract

The annually increasing plastic production volume and therefore the accumulating plastic waste require increasing recycling rates, as the plastic is otherwise landfilled in the environment or thermally recycled. However, the use of recyclates is not approved due to various problems in the processing of recyclates and lower product qualities. In recycling processes, different material streams with varying degrees of contamination and with different colours and additives are joined and compounded into new granules. In addition, additives and colour particles vary in type and amount depending on the season. For example, more packaging is coloured red during the Christmas season than in summer. The varying material composition as well as the material degradation impact the melt viscosity from batch to batch. In order to adapt the process to fluctuating viscosities, one possible influencing variable is the die temperature. By default, the thermal state of extrusion dies is determined by heat sources such as electric heating cartridges or fluid tempering. In addition, cooling in form of convection and conduction occurs in extrusion dies. These temperature control options, while highly effective, are too sluggish to respond to viscosity fluctuations. Therefore, a new approach needs to be developed which allows rapid heat input and removal into and out of the melt. In other applications (such as electronics and aerospace) heat pipes are already used to quickly adjust the temperature in various components. Heat pipes exploit the high enthalpies of condensation and evaporation, so they are able to transfer heat highly efficiently through relatively small cross sections. So far, heat pipes in extrusion dies have only been a research topic for homogenising melt temperatures in the die, but with active cooling and heating, heat pipes offer a highly efficient way to adapt the die temperature close to the flow channel. In order to integrate heat pipes in a binary pre-distributor die used for the extrusion of blown films, viscosity fluctuations are analysed using computational fluid dynamic simulations. Based on the simulation results, the required heat transfer capacity to compensate the viscosity fluctuations is determined so that suitable heat pipes can be selected. The selected heat pipes will be integrated in the pe-distributor die to investigate the effect of active cooling and heating in practical trials. During the experiments, the viscosity is measured inline via a soft sensor based on pressure measurements. Depending on the viscosity at the die inlet, the temperature control of the heat pipes is adjusted to compensate for any occurring viscosity fluctuations.

About the Presenter

Lisa Leuchtenberger studied Business Administration and Engineering: Mechanical Engineering at the RWTH Aachen University, Germany, specializing in plastics technology (Bachelor and Master). She wrote her master's thesis at the Institute for Plastics Processing at RWTH Aachen University in the field of extrusion die design supported by computational fluid dynamics simulations.

Career path

• (2019 - present) — Since March 2019, she has been working as a research assistant at the Institute of Plastics Processing at RWTH Aachen University. She is employed in the department Extrusion and Rubber Technology and is responsible for the workgroup Flat film extrusion and die design. Since May 2021, she has also been team leader of the Process Simulation team. Current research focus — Extrusion die design and thermal homogenization of extrusion dies.

Abstract

A new injection molding processing strategy called iMFLUX is becoming popular. iMFLUX is a low constant pressure process for filling and packing the part. Commercial injection molding simulation software traditionally is not designed for this process. However, you can simulate it. This paper will show how to set up and run simulations using currently available simulation software. Validation work done to date will also be discussed.

About the Presenter

Jay started working in a family-owned machine shop. After Western Michigan University Jay started with Moldflow /Autodesk for 36 years. Jay worked in consulting, customer support, training delivery & development and certification. Jay is the editor of the book Moldflow Design Guide, published by Hanser. Today, works for iMFLUX . At iMFLUX Jay, runs Moldflow to support, the iMFLUX mold shop, R&D to develop methods for simulating the iMFLUX technology and to validate how well Simulation models iMFLUX technology, Sales to use Moldflow to show benefits of using the iMFLUX technology, and iMFLUX customers so they can run simulations themselves. Jay is also an Adjunct Assistant Professor at WMU since 1985, teaching tooling, plastics processing classes. Jay has been member of SPE since 1983. In 2011, Jay was awarded the SPE Mold Making and Mold Design Division's Mold Designer of the year.

Abstract

Due to the viscoelastic flow characteristics of polyethylene (PE) and the interaction of molten PE with metallurgy of a die surface, flow instabilities occur after exceeding a certain shear rate, temperature or mean velocity, which was initially discovered in 1958. This flow instability and melt fracture leads to an undesirable product appearance and can negatively impact product properties due to the emergence of a "sharkskin" morphology of produced film. In addition, melt fracture is one of the first instabilities that occurs at higher throughput, which can limit rates of commercial applications. Although the flow characteristics of polyethylene cannot be modified easily, specialty additives such as polymer processing aids (PPAs) can deposit on the die surface, inducing slip and enhancing flow. With this additional lubrication, die pressure can be lowered and the onset for melt fracture can be delayed, leading to significant commercial rate improvements. Fluoropolymers are ubiquitous within the field of PPAs for polyethylene and incorporate fully-fluorinated carbons to reduce interactions of the molten polyethylene and the die surface. While the efficacy of fluoropolymers to delay the onset of melt fracture is well described, the current regulatory landscape is progressing rapidly for the broad ban of perfluoroalkyl substances, which incorporates fluoropolymers. Although the chemistry and migration of fluoropolymers is quite different than that of perfluorooctanoic acid and perfluorooctanesulfonic acid which bans initially targeted, the current legislations are covering all compounds with at least one fully fluorinated carbon. Regarding plastic packaging, there are multiple states that have passed bans effective in 2023, with additional regulations going through the US and EU that come into effect within the next few years. For converters and film producers to maintain current rates and product morphology, new PFAS-Free technology needs to be developed and implemented within a very short timeframe. This presentation will provide insight into the mechanism at which processing aids lubricate the die and reduce melt fracture, cover academic and literature-based PFAS-Free PPA technologies and deliver an overview into the development of PFAS-Free PPAs at NOVA Chemicals. The performance of NOVA Chemicals fluorine-free PPA technology and efficacy towards melt fracture clearing will be presented alongside the effectiveness of fluorine-free PPA to prevent die lip build up.

About the Presenter

Josh Heidebrecht is a Research Scientist for NOVA Chemicals' Product Safety and Additives Technology team located in Calgary, Alberta. In his role, Josh is involved in the development and evaluation of fluorine-free polymer processing aids, responsible for evaluating new additive-based technologies for polyethylene applications and provides customer support for additives-related topics. Josh obtained a MSc in Chemistry from the University of Calgary and has been with NOVA Chemicals since early 2019

Abstract

With climate change worsening, people have become more conscious of their environmental impact. Companies are receiving growing pressure to use increasing content of post-consumer recycled (PCR) plastics in their products. However, PCR plastics differ from virgin materials in several mechanical, physical, and rheological properties, posing design and molding challenges for manufacturers. In this work, a polypropylene (PP) compound is produced and characterized using different contents of PCR PP to model its properties as a function of PCR content. A numerical approach is then proposed to determine the maximum content of PCR PP suitable for a given application. Furthermore, a robust design approach is proposed to identify engineering changes for both part and mold design that can make the part performance insensitive to lot-to-lot variations of the PCR properties.

About the Presenter

Dr. Giovanni Lucchetta is Associate Professor in Manufacturing Engineering at the University of Padova. His research is focused on forming technologies of polymeric materials and microtechnologies, particularly in injection molding. The main research topics are: i) Replication of microstructured and nanostructured surfaces for microfluidic and biomedical applications with particular reference to the analysis and modeling of replication and ejection of high aspect ratio features. ii) Injection molding of polymer compounds, with particular reference to the analysis and modeling of the orientation and concentration of filler particles, to the development of technologies for the rapid variation of the mold temperature, and to the study of their effects on surface properties of the molded parts. iii) Modeling and characterization of the tribological effects of the mold surface properties in the injection micro-molding process to produce complex 3D parts and improve both the filling flow of the polymer melt in narrow cavities and the ejection of the molded micro parts. Prof. Lucchetta has participated in several national and international research projects evaluated by peer review. As an Associate Member of the International Academy for Production Engineering (CIRP), Prof. Lucchetta has an active role in Scientific Technical Committees on Surfaces and Forming. He has been a member of the Polymer Processing Society (PPS) community since 2010 and president of the Italian Division of the Society of Plastics Engineers (SPE). Prof. Lucchetta is the author of 121 publications in international journals or proceedings of indexed international conferences. The majority of these are related to injection molding and published in peer-reviewed journals (H-index: 23. Total citations: 1564)

Abstract

The single-screw extruder is one of the most important plastics processing machines. In order to improve the design of the machines and in order to predict relevant process variables, computer-aided approaches as three-dimensional simulation are increasingly coming to the fore. Depending on the process zone, different modeling approaches are used. For the feed zone, the so-called Discrete Element Method (DEM) is becoming increasingly important. For the melting zone, Computational Fluid Dynamics (CFD) is predominantly used with sub methods like the Finite Volume Method (FVM). However, to date, no method has been explored that allows joint consideration of the feed zone and the melting zone. In this paper, building on the authors' recent work, a novel approach is presented that allows a joint consideration of these zones. The approach explored is based - for the first time in the case of the single-screw extruder - on a coupled CFD-DEM method. The approach pursued represents a three-phase model. It is based on the Volume of Fluid (VoF) Method and couples it with DEM. In this work, the melting process in the single-screw extruder is simulated using the new approach with joint consideration of the feed zone and the melting zone. To calculate the melting process, a melting model recently published by the authors is used. The results are compared with experimental investigations.

About the Presenter

Born in Germany in year 1991 - studied Mechanical Engineering (Dipl.-Ing.) at TU Kaiserslautern, Germany - started working as a phd-student at Institut für Kunststofftechnik, University of Stuttgart beginning 08/2017 - Current Position: Head of Plast

Abstract

In injection molding of fiber-reinforced thermoplastics, in the presence of physical obstacles, such as cores, or for geometries that require multiple gates, weld lines develop where flow fronts rejoin. Regions affected by the presence of weld surfaces show worse mechanical properties. In fact, these areas are characterized by incomplete welding between the flow fronts and the presence of undesirable inclusions and porosity. In addition, due to the fountain-like flow in cavities, fibers on the weld line are unfavorably arranged and are unable to reorient themselves in the flow direction. If the incident flow fronts exhibit no pressure gradient during the defect formation and the holding phase, the morphology of the weld surface remains unchanged until the end of the process. By inducing a pressure imbalance after the formation of the weld line, on the other hand, it is possible to promote the interpenetration of one front into the other and significantly modify the local morphology. A dynamic packing stage during the first part of the holding phase therefore allows for improved matrix interdiffusion at the interface and fibers reorientation in the flow direction. Gas Assisted Injection Molding (GAPP) is a novel technology that allows for the dynamic packing of weld lines using only a single injection unit. Thanks to miniaturized gas injectors, it is possible to manipulate the molten polymer in the cavity and generate a flow through the weld surface. The dynamic packing achieved using GAPP allows for the elimination of weld lines in the core layer of the molded part, significantly increasing its mechanical performance. For a 35% glass fiber reinforced polypropylene, an increase in tensile strength and stiffness of 240% and 21.5%, respectively, can be observed in the defect region. GAPP can be implemented to solve weld line strength problems in all parts made of fiber-reinforced thermoplastics that require high mechanical performance, such as supports, brackets, cooling fans, pulleys, and other structural parts.

About the Presenter

Marco Sorgato is Research Fellow in Manufacturing Technologies and Production Systems at the Department of Industrial Engineering (DII) of the University of Padova. In 2016, he received the PhD in Industrial Engineering with the thesis entitled "Characterization of the micro injection moulding of micro- and nano-structured polymer surfaces". His main research activities focus on micro technologies, with particular reference to micro injection molding. The main investigated topics are related with:

1. Development of innovative process chains for the realization of micro and nano structured polymer surfaces;
2. Characterization of the effects of mold surface properties on both the filling and the demolding phase in micro injection molding;
3. Analysis of the feasibility of using additive manufacturing technique for the realization of micro-structured mold inserts for micro injection molding of micro fluidic devices.

Marco Sorgato is author of 82 papers in refereed journals and international conference proceedings. He participates as presenter at more than 30 international conferences in the field of polymer processing and micro manufacturing . He was member of the International Academy for Production Engineering (CIRP), Polymer Processing Society (PPS), Society of Plastic Engineering (SPE) and Associazione Italiana di Tecnologia Meccanica (AITeM).

Abstract

Polymer materials are made fire resistant basically by controlling either the bulk properties of polymers i.e., the condensed phase or by controlling the gas phase chemistry i.e., the volatiles that are formed due to polymer degradation under burning conditions or by controlling both. This suggests that if materials could be designed with low specific mass loss rates under fire conditions, the amounts of volatiles formed would be substantially reduced resulting into less combustion and thereby less heat generation. The latter would result into less increase of surface or ignition temperature of the materials resulting into less thermal degradation of materials. This suggests that important parameters that control the condensed phase properties of polymers to make them fire resistant are surface or ignition temperature and the kinetic degradation parameters of the materials. Another parameter that has a great influence on the fire properties is the gas phase chemistry, which in turn, is controlled by the volatiles formed during the burning process. The volatiles formed differs both with respect to flammability and generation of heat of combustion. This suggests that both the total amount of volatiles and the chemical composition of the volatiles formed because of burning are important to improve fire resistance properties of the materials. Therefore, preferred volatile compositions are also presumed to be effectively improve the fire properties of the materials. Furthermore, in phosphorus (P) and Phosphorus-Nitrogen (P-N) based (PFR) halogen free flame-retardant systems, it has been suggested that formation of P and PO radicals in the gas phase are important to obtain good fire-resistant properties because they both function as effective radical quenchers and char formers resulting into less heat generation. For radical quenching presence of phosphorus in the form of P and PO radicals in the gas phase are important. This suggests that distribution of phosphorus both in the condensed and in the gas phase should play an important role in controlling the fire properties. This proposes that selection of suitable PFR compounds that renders a preferred P distribution in the gas and in the condensed phase is important to obtain good fire resistance properties. Unfortunately, quantitative estimations of the above-mentioned parameters are lacking in the literature. In this presentation, we shall present a toolkit to experimentally measure these parameters for different HFFR PP model compounds and their correlations to the UL94V results. The study shows that we obtain a good agreement between these quantitative parameters and UL94V tests. This suggests that our toolbox could be very helpful and effective tool both to characterize and develop new and effective HFFR formulations instead of using single point UL94V tests that are being commonly used today.

About the Presenter

Dr. Swaraj Paul took his MSc degree from Agra University in India and PhD degree from Royal Institute of Technology, Stockholm, Department of Polymer technology in 1975 on the synthesis of acrylic polymers. He received his D Sc (Docent) degree from Royal Institute in 1979. After that he has worked in different industries such as Beckers, SOAB and ABB Plastics for 11 years. Since 1985, he is running his own research and development company, PP Polymer AB, which has specialised mainly in the chemistry of surface coatings, adhesives and polymeric materials. He is also CTO for the sister company, Paxymer AB since 2010. He has been the course director for Environmentally Favourable Coatings organized by CEI/Elsevier during 1987–1989 in Davos. He has authored the book, ‚"Surface Coatings: Science & Technology", John Wiley 1985 and co-authored the multi-authored "Comprehensive Polymer Science", Pergamon Press 1989 and the second edition of ‚"Surface Coatings", John Wiley 1996. He has been President for Federation of Scandinavian Paint and Varnish Technologists during 2000-2003. In 2012 he was awarded the Chemical Technology Prize for his invention of halogen free flame retardant for polymers, Paxymer by Swedish Society for Chemical Engineers. In March 2015 he was selected as one of the experts for EU's Horizon 2020, FoF (Factories of Future). In 2015-2016 he chaired the review committee for the grant of 6 million Euro research call on "Plastics in Sustainable Society" for MISTRA (The Swedish Foundation for Strategic Environmental Research). In 2015, Swaraj Paul was invited to present a keynote paper and tech corner on flame retardants at China Coat in Shanghai. In 2017, he presented a paper on Paxymer at the AMI Conference on Flame Retardancy of Polymer Materials.

Abstract

Material selection during the design phase can dictate a final part's ability to be recycled or not. This paper looks at an appearance part that transformed three different material solutions into a single material solution such that the final part was now recyclable and produced at lower cost. A look at the technical challenges and solutions to achieve this result is included.

About the Presenter

Bruce received a B.S. degree in Chemical Engineering from Rensselaer Polytechnic Institute in 1980. He is now retired from Celanese where he was the Global Color Technology Director. Bruce has been involved with all aspects of appearance including color development, gloss control and UV stabilization. He was with Celanese for 35 years. Bruce is an Honored Fellow of the Society of Plastics Engineers, having achieved both Fellow and Honored Service Member status. Bruce is very active within the Color & Appearance Division, where he is currently a member of the Board of Directors, Division Treasurer, past Councilor, and a past chairman. Bruce is currently the President-Elect of SPE, starting his term as President of the Society on January 1st, 2023. He is also a member of the Detroit Color Council. Bruce has presented numerous papers on coloring and UV stabilization, and holds several patents in those areas.

Abstract

All sections of a single-screw extruder must be operating well to maintain the maximum profitability of the line. The solids conveying section must be able to operate at a rate high enough to keep the metering section full of resin and pressurized. Optimal solids conveying depends on the forwarding and retarding forces on the solid bed, and these forces depend on the barrel and screw temperatures. Usually, a considerable level of care is given to setting the barrel and feed casing temperatures. The temperature of the screw, however, is typically not controlled. Instead, the screw temperature is unknown and often hotter than optimal. Screw cooling can improve solids conveying for many processes. This paper discusses fundamentals and operational practices for using screw cooling.

About the Presenter

Tim Womer is the President of TWWomer & Associates, LLC. He was the 2006-2007 President of the Society of Plastics Engineers and served on the SPE Extrusion Board of Directors for over 22 years including serving as a Chairman in 1999-2000. Tim is a recognized authority in plastics technology and machinery with a career spanning over 40 years; having worked for other companies such as Xaloy, Inc., Spirex Corporation, Conair Group and NRM Corporation. Tim has designed thousands of screws that have been used in all areas of single-screw plasticizing, such as extrusion, blow molding and injection molding. Numerous patents have been issued for his inventions of screws, mixers, processes and other products. In 2012, Tim was inducted into the Plastics Hall of Fame for his contributions to the Plastics Industry, currently the Senior Vice-President of the Plastics Hall of Fame and is also active member of the Plastics Pioneers Association. Tim is only one of six SPE members to ever receive three of SPE's highest awards which include, Distinguished Member, Honored Service and Fellows. Tim remains active in SPE by speaking at various SPE events and serving on the Grants Committee of the SPE Foundation.

Abstract

Moxietec has developed a technique to injection mold thick thermoplastic foams which display impressive mechanical properties while enjoying significant weight reduction relative to the solid counterparts. Because the foam molding requires less polymer mass to achieve a given geometry, thickness more than one inch and up to nine inches can be molded in relatively quick cycle times. Mechanical property development as a function of part density will be discussed relative to other engineering and structural materials, and design strategies for atypically thick thermoplastic parts will also be discussed. Sustainability of the process will be discussed with regard to cycle time, energy consumption and recyclability.

About the Presenter

Dr. Alicyn Rhoades specializes in polymer thermodynamics, with active research in polymer crystallization using fast-scanning calorimetry techniques. She also has active research projects focusing on polymer composite formulation as well as materials for additive manufacturing. She is also a graduate faculty member of the Materials Science and Engineering (MatSE) Department at Penn State University. She has worked with Moxietec since 2019 and is a named inventor on four Moxietec issued patents. Dr. Rhoades received the Ph.D. in Polymer Science and Engineering (2006) from The University of Southern Mississippi with a graduate minor program in Commercializing Technology. She received her B.S. in Plastics Engineering Technology (2001) from Penn State Erie, The Behrend College.

Abstract

Photolytic and thermal degradation are important processes to the overall sustainability and environmental impact of a flame retardant for a given commercial application. Details on accelerated photolytic aging and recycling studies of ethane bis(pentabromophenyl) (EBP), often called decabromodiphenyl ethane (DBDPE), will be presented.

About the Presenter

Mathur Rajeev is a Senior Advisor at Albemarle Corporation where he has worked for over 24 years in R&D and Customer Technical Service.

Abstract

About 4 billion people around the world are suffering from water scarcity, which is expected to increase due to increasing global warming. One of the solutions to address the water scarcity challenge is to tap the 13,000 trillion of water present in the atmospheric air in the form of fog, droplets, or vapor. Simple fog collection systems effectively harvest water without investing energy in highly humid environments, but they are ineffective in arid regions like Arizona, where the humidity is low. Alternatively, adsorbents designed to capture water vapor during colder nights and release it during the hotter day could provide a passive solution to harvest water vapor in the arid regions of the world. Recently, porous polymeric hydrogels have been reported for water droplets harvesting from the air. The gels were fabricated with thermoresponsive polymers, such as polypyrrole chloride penetrated PNIPAM, that can switch to hydrophilic and hydrophobic structures at lower critical solution temperature (LCST) and upper critical solution temperature (UCST), respectively. By leveraging their switchable wetting properties, the water droplets were captured during the night at higher humidity and lower temperature conditions and collected during the day at lower humidity and higher temperature conditions. However, the influence of LC/UCST on the hydrogel's chemical and morphological structures has not been investigated, as well as harvesting water vapor present in arid regions. In this work, we report the fabrication of thermoresponsive P(NIPAM-co-BzDMA) copolymeric hydrogel to collect water vapor from the air across all humidity conditions. The hydrogels were fabricated by tuning the temperatures and compositions to achieve large surface area-to-volume ratios, ordered porous structures, and excellent switch between the hydrophilic-hydrophobic wetting properties. The gels synthesized at LCST at BzDMA salt concentration of 15% could uptake 20% higher water than their counterparts.

About the Presenter

Dr. Pavani Cherukupally is a Banting Postdoctoral Fellow of Circular Materials at Massachusetts Institute of Technology (MIT), USA, and a Scientific Contributor at Advanced Science News and Nature Sustainability Blog. Dr, Cherukupally develops materials-based sustainable technologies to address grand challenges, such as water, energy, and environmental remediation. She invented novel sponge-based adsorption technology for oil field wastewater remediation, resource recovery, and disinfection. The Canadian and UK governments have invested over $2.5 M to scale up the sponge technology to clean marine oil spills and wastewater disinfection. Dr. Cherukupally has filed 2 patent applications and published 15 peer-reviewed articles in tier-I journals of Nature, Science, American Chemical Society, American Institute of Physics Publishing, and international polymer conferences. She has received several awards for research and leadership contributions, including Asian Women of Achievement by Accenture and NatWest, Outstanding Postdoctoral Fellow and Next Generation of BlueSky Thinkers at Imperial College London in the UK; Research Excellence Recognition Award by New York Academy of Sciences and PepsiCo., and Rising Stars in Chemical Engineering at MIT in the USA; and Banting and NSERC Postdoctoral Fellowships in Canada. DR. Cherukupally is also a Science Alliance Leadership Fellow of the New York Academy of Sciences and Lockheed Martin. Various news outlets, including the Hindustan Times, New Scientist, Science Magazine, and Nature Sustainability Editorial, featured Dr. Cherukupally's work.

Abstract

Previous research has shown that the barrel rotation and screw rotation physics for single-screw extruders produce identical fluid flows for isothermal, Newtonian fluids. When energy dissipation and thermal affects are added, barrel rotation physics causes the temperature in the channels to be higher than that for screw rotation. The focus of this investigation is to show the effect of rotation physics for the simplified geometry of a Couette rheometer.

About the Presenter

Dr. Jin is a research scientist in Compounding and Extrusion R&D at the Dow Chemical. She got her Ph.D in polymer science from Case Western Reserve University.

Abstract

Today, the need for micro molding applications is rapidly increasing, in part due to advancements in technology and scientific research. With medical devices becoming less invasive, and portable/wearable health devices gaining popularity, the need for small and highly precise components and parts has increased. Micro molding can be used to manufacture parts for these devices meeting the need for fine features, thin walls, micro holes, tight tolerances and scalability to high volume production. However, there are many challenges in molding micro parts or molding micro features and/or tight tolerances on small parts. This presentation will review some of the challenges involved in molding micro parts, sharps, micro holes, thin walls and micro automated assemblies and solutions for overcoming these challenges including resin selection and precision tooling considerations. In addition, we will discuss emerging applications where these micro advancements are required, including specialty surfaces.

About the Presenter

With over 34 years of industry experience, Donna Bibber has developed thousands of miniaturized devices incorporating micro molding and automated assembly. Ms. Bibber received her Bachelor of Science in Plastics Engineering from the University of Massachusetts Lowell and is currently the CEO of Isometric Micro Molding, Inc. Ms. Bibber's plastics engineering background, expertise and unique problem-solving skills have earned her an excellent reputation and national and international recognition for her work in micro manufacturing. She has been a featured speaker at medical and drug delivery conferences across the globe and has published countless technical papers on micro molding and micro assembly. Her expertise in bioresorbable polymers and active ingredient combination devices, slow-release devices, ophthalmic devices and implants, glucose monitoring and insulin-delivery devices, neurological implants, biosensors, and oncology markers have given rise to many platform-type miniaturized devices commercially available today.

Abstract

Micro 3D printing is emerging as a viable technology to not only produce micro-sized parts but can be also used to create 3D printed molds. This means components and parts for medical and drug delivery devices can be produced quickly and cost-effectively with greater flexibility. In this presentation we will discuss the advantages and disadvantages of 3D printed parts; parts molded from 3D printed molds; and parts molded from traditional metal molds.

About the Presenter

With over 34 years of industry experience, Donna Bibber has developed thousands of miniaturized devices incorporating micro molding and automated assembly. Ms. Bibber received her Bachelor of Science in Plastics Engineering from the University of Massachusetts Lowell and is currently the CEO of Isometric Micro Molding, Inc. Ms. Bibber's plastics engineering background, expertise and unique problem-solving skills have earned her an excellent reputation and national and international recognition for her work in micro manufacturing. She has been a featured speaker at medical and drug delivery conferences across the globe and has published countless technical papers on micro molding and micro assembly. Her expertise in bioresorbable polymers and active ingredient combination devices, slow-release devices, ophthalmic devices and implants, glucose monitoring and insulin-delivery devices, neurological implants, biosensors, and oncology markers have given rise to many platform-type miniaturized devices commercially available today.

Workshop Overview

This workshop is designed to view the obstacles of plastic manufacturing from the perspective of the end product owner. Pinpointing an issue gets easier the closer you get to the manufacturing source, but what happens if you're not near the source or if you don't know which path to use to track down the problem? The workshop will include a speaker who has experience dealing with these rabbit holes and how to recognize what issues matter and what aren't really issues, discussing how to approach a problem of a plastic product, creating a troubleshooting mindset to systematically attack the issue instead of just jumping in without an organized plan thought out. The speaker will be followed by a roundtable of experts in different fields and plastics processes, offering up how they target their product issues.

About the Instructors

Lynzie Nebel is an Upstream Quote Engineer for Cytiva, managing the product costing for custom upstream hardware equipment for bioprocessing. Throughout her career, Lynzie has gained experience in the automotive, appliance, medical, pet, and micro-injection molding industries.

Lynzie received her Bachelor of Science degree in Plastics Engineering Technology from Penn State Behrend in 2008. She has been a member of SPE since 2004 and has been involved in her local section, holding many positions including past President. Lynzie also sits on the Injection Molding Division board, and is the former secretary for the SPE Foundation board. She is currently the Vice President of Member Engagement on the Executive Board for SPE. In 2015, Lynzie was part of Plastics News' inaugural class of "Women Breaking the Mold," and was named one of the group's "Rising Stars" in 2018. She is also on the Industrial Advisory Board for Penn State's Plastics Department.

David J. Anzini is a Manager of Research & Development for Celgard, with an office located in Charlotte, North Carolina. Celgard is a global leader in the development and production of high-performance membrane technology which is found in lithium-ion batteries and other demanding applications, such as performance textiles and specialty filtration applications. Prior to this, Dave held positions at Zip-Pak, Pactiv, Conwed Plastics, and Mobil Chemical. He holds an MS and a BS in Chemical Engineering from the University of Connecticut and has spent 40-plus years in the plastics and packaging industries.  Dave holds multiple patents and has several patent applications pending. He also serves on the Extrusion Division Board of Directors.

Workshop Overview

The course will give an introduction to polymer stabilization in topics such as processing, long thermal, and UV stabilization of major thermoplastics.

Target Audience

The workshop is intended for those new to the field as this area is not typically taught during formal college education, but is essential to the commercial and technical viability of the major thermoplastic polymers.

About the Instructor

Roger Avakian was the Technical Director for over ten years at General Electric, Specialty Chemicals Division, which produced processing stabilizers, and formulated various stabilizer packages. Roger is also an inventor of several stabilizers. He also has over forty-seven years experience in polymers and additives.

Gary Wnek is the Joseph F. Toot, Jr., Professor of Engineering and Professor and Chair of Macromolecular Science and Engineering at Case Western Reserve University. He was previously a faculty member in The Department of Materials Science and Engineering at MIT and the Department of Chemistry at RPI, and was the Founding Chair of the Department of Chemical Engineering at Virginia Commonwealth University in its new School of Engineering. His research interests include processing of polymer multi-layer and polymer fiber/matrix composites, flammability mitigation of common polymers, fibrous polymers and gels for applications in drug delivery and regenerative medicine, and synthetic macromolecular constructs that mimic physiological functions. He has authored or co-authored over 200 publications and holds 37 US patents. He received the 2007 John W. Hyatt Award (benefit to society) from the Society of Plastics Engineers for his work on polymer nano- and microfibers for regenerative medicine and related biomedical applications.

Gary earned his Ph.D. In Polymer Science and Engineering at the University of Massachusetts, Amherst, in 1980, and his B.S. Degree in Chemical Engineering at Worcester Polytechnic Institute in 1977.

Workshop Overview

This workshop will introduce participants to applications of AI for materials and product development, and manufacturing processes, covering basic concepts, and how AI and domain knowledge can be leveraged to accelerate processes, reduce costs, and innovate products. Participants will be engaged in an end-to-end AI modeling workflow on product development case studies. Participants will learn: How to apply AI in product development; How to select the right projects for AI; Basic materials informatics concepts.

Target Audience

The workshop is intended for industrial professionals, researchers, business leaders, and managers who would like to have a deeper understanding of AI in materials science and engineering and related manufacturing processes. No previous AI knowledge or coding experience is required.

About the Instructor

Dr. Maryam Emami is the CEO of AI Materia, a materials and manufacturing informatics company, helping the industry to accelerate the development and deployment of next-generation materials and products. With over 15 years of experience in advanced materials and manufacturing, Dr. Emami is a recognized and visionary leader in digital transformation and innovation in the industry. Under Dr. Emami's leadership, AI Materia has explored new frontiers of AI in the field. Her commitment to excellence and drive for results have been instrumental in the company's success and AI Materia continues to be at the forefront of shaping the future of the industry.

Dr. Emami holds a Ph.D. in Chemical Engineering from McMaster University and a bachelor’s degree in petroleum engineering. She is a designated professional engineer.

Workshop Overview

The most efficient and effective approach to plastic component failure isperforming a systematic failure analysis following scientific method. Someone once said, “If you don't know how something broke, you can't fix it,” highlighting the importance of a thoroughunderstanding of how and why a product has failed.

• Possible Outline Plastic Properties: chemicalthermal, mechanical
• Recognizing Failure Plastic Failure Mechanisms: impact, creep, ESC, fatigue,degradation
• Conducting a Failure Analysis Failure Analysis Testing: fractography and analytical

This course would be "case study" and "example" driven.

Target Audience

Target audience are those responsible for the design and quality of molded plastic components and equipment using plastic parts. This includes automotive, medical, appliance, aerospace, electronics industries. Typical titles would be plasti cengineers, engineering managers, quality engineers, reliability engineers, design engineers.

About the Instructor

The Madison Group performs hundreds of failure investigations every year. Jeff Jansen has personally conducted over 5,000 in his career. This is a core competency of The Madison Group and himself. They teach a 3-course in failure analysis and prevention through the University of Wisconsin - Milwaukee, and Jeff also gives personalized training for individual clients.

Workshop Overview

This workshop is intended as an introductory primer in patent law and practice for scientists, engineers and managers involved in business and technology. The workshop provides an overview of patent protection and trade secret protection. The workshop also covers the fundamentals of how to identify, and document an invention, search for patents related to the invention, and apply for a patent application. In particular, attendees will become familiar with the types of patent applications, patentability requirements, the parts of a patent application, and the prosecution process for getting a patent application allowed before the U.S. Patent and Trademark Office (USPTO). Attendees will also become familiar with foreign filing of patent applications, post grant patent options including mechanisms for challenging a U.S. patent before the USPTO, the various types of patent opinions and patent litigation. No prior knowledge of patent law is required.

Agenda is as follows:

• Patents – Introduction
• Trade secrets
• Inventorship
• Invention documentation
• Types of Patents
• Patent procurement process overview
• Patent searching
• Patentability requirements
• U.S. Patent Application Filing Formalities
• How to read a U.S. patent publication
• Patent application preparation
• Patent prosecution
• Foreign filing and prosecution
• Post grant options
• Patent litigation and infringement
• Patent opinions

Target Audience

This workshop is for anyone involved in technology development, and business related to new technologies who needs a thorough understanding of intellectual property and in particular patent law fundamentals.

Are you involved in technology development? Learn how to identify, document and protect your inventions through the patenting process. What you think may not be worthy of a patent protection may in fact be an invention that could lead to highly valuable patent that could block your competitors and bring tremendous business value. Learn how to work with patent counsel to effectively prepare, prosecute and file patent applications. Don't let your ideas and technology work go unprotected!

About the Instructor

Robert Migliorini has been teaching a similar type workshop for over 15 years. His experience is as follows: A Senior Licensing Associate in the technology transfer office at Yale University and also an independent Patent Attorney. Prior to that, he worked for 18 years as a Senior IP counsel with Exxon Mobil Corporation where he assisted clients in all aspects of IP law, including patent preparation and prosecution, patent opinions, client counseling, and IP agreements and licensing. He is an author or coauthor of six IP journal articles related to patent law. Prior to becoming an attorney, Robert worked for 17 years for ExxonMobil Chemical Co., Films Business, in a variety of technical, operations and leadership positions. He is also an inventor or coinventor of 14 U.S. patents related to thermoplastic and metallized films. He also has extensive experience in coating, printing, metallizing and laminating technology. He is licensed to practice law in various states and before the U.S. Patent and Trademark Office. Robert is also an adjunct law professor at both Pace University School of Law and Quinnipiac University School of Law where he teaches courses in Patent Practice & Procedure and IP Agreements & Licensing to law students.

Workshop Overview

This workshop is intended for engineers, scientists and professionals already in the medical materials field who are looking for fresh insights into recent trends; as well as students, engineers, scientists and professionals who are not currently in the field, or are new to it but who are interested in learning more about medical material fundamentals along with recent trends in the medical materials field. Due to the complexity of the medical technology field, there are many new developments of which engineers, professionals, suppliers, manufacturers and other stakeholders may not be aware. This workshop will help broaden attendees understanding of the field and recent developments. This workshop will be organized into sections addressing (a) industry fundamentals and the evolving regulatory framework, (b) work-horse materials for industry sectors, (c) Industry drivers including sustainability and environmental issues, and (d) emerging materials for the life sciences.

Who is This Workshop Intended for?

This workshop is intended for engineers, scientists and professionals already in the medical materials field who are looking for fresh insights into recent trends; as well as students, engineers, scientists and professionals who are not currently in the field, or are new to it but who are interested in learning more about medical material fundamentals along with recent trends in the medical materials field.

About the Instructors

The listed instructors from the SPE Medical Plastics Division each have multiple decades of experience in the medical plastics and polymers field. We also have a history of developing and delivering timely, technical and business-relevant information to a range of audiences. For example, we have presented at ANTEC®, TOPCONs, MD&M, and other technical shows and trade shows for the last 40 years. The SPE Medical Plastics Division is planning this team-delivered workshop to leverage the combined insight and experience of our instruction panel to provide adynamic and engaging learning experience.

Workshop Overview

The workshop will describe the most common root causes for high discharge temperatures, rate limitations, flow surging, resin degradation, color mixing problems, and melting limitations to name just a few, Once the root causes are identified, technical solutions will be provided. All troubleshooting problems will be described using actual field case studies and the remedies used to eliminate the problem.

Who is This Workshop Intended for?

People responsible for end-product or salespeople working to solve problems that might not be their material or processes fault.

About the Instructor

Dr. Mark Spalding is a Fellow in Dow Plastics in Midland, Michigan. He joined Dow in 1985 after completing a BS degree from The University of Toledo and a MS and Ph.D. from Purdue University, all in Chemical Engineering.

Mark has held technical positions in Corporate R&D, Polystyrene R&D, Plastics R&D, and INCLOSIA* Solutions. He authored over 170 technical publications. His expertise is in single-screw extrusion and related polymer processing technologies. He co-authored a book with Professor Gregory A. Campbell with the title "Analysis and Troubleshooting of Single-Screw Extruders.

He has solved some of the most complicated extrusion problems at Dow customer’s plants by developing and applying sophisticated troubleshooting methods. He has designed extrusion systems for most of Dow’s major customers for virtually every resin that Dow produces. He is a Fellow and an Honored Service Member of the Society of Plastics Engineers.