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.
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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.
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.
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.
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.
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.
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.
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