Polymer and Organic Materials Commons^™

Upcycling Commodity Polymers To Advanced Materials For Energy And Environmental Sustainability, Anthony Griffin-Espinoza

Dissertations

Synthetic polymers play an essential role in nearly every aspect of our lives. Extending beyond single-use packaging, polymeric material design has progressed to attain tailorable architectures granting exceptional performance across advanced applications, including carbon-fiber reinforced polymer composites for aerospace, conductive materials for soft electronics, and drug carriers for biomedicine. While highly promising, intricately designed polymers needed to achieve excellent performance often have limited processability, complex synthetic methods, and expensive precursors. Furthermore, due to a lack of recyclability, commodity polymer waste streams result in both environmental impacts and a substantial loss of economic value. This dissertation focuses on developing robust strategies …

Biobased Acrylate Composites With Enhanced Strength For Additive Manufacturing, Nicole Wagner, Joseph Mcwherter

Engineering Faculty Articles and Research

With the expanding use of polymers in additive manufacturing, sustainable resins for use in vat photopolymerization are required to reduce their environmental impact. One promising approach to achieve this is to incorporate biobased fillers that replace the acrylates in photopolymer resins as ‘green’ alternatives. In this study, photopolymer composites consisting of a methacrylate resin with varying calcium carbonate powder content between 0 and 50 wt.% were investigated. A digital light processing technique was used to fabricate tensile test specimens for mechanical testing. Good printability, dimensional accuracy, and good interlayer adhesion were observed for composite resin formulations that incorporated calcium carbonate …

Design And Manufacturing Of Multifunctional Piezoelectric Composites, Huan Zhao

Dartmouth College Ph.D Dissertations

Piezoelectric materials possess a unique ability to convert mechanical energy into electrical signals and have broad industrial applications. However, monolithic piezoelectric materials such as piezoceramics and piezopolymers often suffer from inherent trade-offs among mechanical strength, elasticity, and durability. Piezoelectric composites, typically consisting of a polymer matrix with ceramic reinforcements, offer a solution by combining the advantages of each constituent. Nevertheless, maintaining stable mechanical performance in high-temperature environments remains a significant challenge as conventional polymer matrices usually experience structural degradation.

In this thesis, a novel piezoelectric composite is developed using a preceramic polymer (PCP) matrix with barium titanate (BTO) inclusions. PCPs …

Synergistic Strategies In Hybrid Mxed Matrix 3d Printing Of Thermoplastics & Thermosets: Design, Manufacturing, And Materials Development., Saleh Akram Khanjar

Electronic Theses and Dissertations

Composite manufacturing and mixed matrix structures have been produced using traditional manufacturing processes for various industrial applications due to their high mechanical properties to material weight and cost ratio. However implementation of composite and mixed matrix manufacturing with advanced manufacturing such as additive manufacturing is limited due to the hardware limitations of current 3d printing technologies and materials available for 3D printing applications. This work has developed and investigated a new hybrid 3D printing manufacturing process utilizing a variety of material systems (thermoplastic – thermoset, thermoplastic – thermoplastic, thermoset – thermoset, thermoplastic – thermoplastic – thermoset). This study developed thermoplastic …

Process-Structure-Property-Performance Modeling For Semicrystalline Thermoplastics And Composites, Tatiana Stepanova

All Dissertations

With a growing focus on reducing the adverse effects of transportation on the environment, industries are seeking fuel-efficient and sustainable solutions. Fuel efficiency can be improved in several ways, but structural lightweighting has demonstrated overall effectiveness. In this regard, thermoplastic composites and additive manufacturing (AM) thermoplastics have become viable candidates for use in the automotive industry, given the need for weight reduction and efficiency improvement.

The advantages of AM include simplifying supply chains, simplifying part geometry, and enabling mass customization. In order to design high-performance AM structures, extensive modeling and simulation are required. AM thermoplastics are similar to conventional manufacturing …

Investigating The Role Of Tesserae In Energy Absorption In Shark Cartilage, Molly Dobrow

UNF Graduate Theses and Dissertations

Unlike mammals, shark endoskeletons are composed of cartilage, which is less stiff compared to bone. Despite this structural disadvantage, sharks have risen to become apex predators, with reported maximum posterior bite force estimates approximating 5914 N in bull sharks. Shark jaws are estimated to undergo high cycle loading within the organism’s lifecycle without evidence of failure. Fatigue resistance may relate to mineral distribution within a component of the endoskeletal system – tesserae. Tesserae are thin, roughly hexagonal tiles composed of calcium phosphate hydroxyapatite (HA) crystals and grow by accretion to eventually surround the hyaline cartilage core. Though tesserae dimensions are …

Characterization Of Interlayer Laser Shock Peening During Fused Filament Fabrication Of Polylactic Acid (Pla), Fabien Denise

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The field of additive manufacturing (AM) has gained a significant amount of popularity due to the increasing need for more sustainable manufacturing techniques and the adaptive development of complex product geometries. The problem is that AM parts routinely exhibit flaws or weaknesses that affect functionality or performance. Over the years, surface treatments have been developed to compensate certain flaws or weaknesses in manufactured products. Combining surface treatments with the modularity of additive manufacturing could lead to more adaptable and creative improvements of product functions in the future. The current work evaluates the feasibility of pursuing a new research axis in …

Effects Of Sizing Agents On Mechanical Properties Of Carbon Fiber–Polymer Composites Via Fused Filament Fabrication Additive Manufacturing., Benjamin D. Mitchell

Electronic Theses and Dissertations

This study demonstrated the effects of changing the sizing agent parameter during the preparation of carbon fibers on the mechanical properties of composite made with acrylonitrile butadiene styrene (ABS) as the matrix material and carbon fibers as the fiber material. Three types of sizing agents produced by Allnex were used to coat three different batches of carbon fibers that were mixed with a torque rheometer and extruded with a barrel-style melt extruder into continuous spools of 1.75 mm filament for use with commercial 3D printers. Tensile tests were conducted on the filaments and tensile bars printed from the materials. Results …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

LSU New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Additive Manufacturing Waste Management System - Plastic Extrusion Process, Gabriel Bennett, Lindsay Liebrecht, David Lyogky, Wilson Woods

Williams Honors College, Honors Research Projects

3D printing is a fast-growing market with its main source of waste being PLA and ABS plastics. In 2019, the global additive manufacturing market grew to over $10.4 billion, crossing the pivotal double-digit billion threshold for the first time in its nearly 40-year history. (SmarTech Analysis, 2020 Additive Manufacturing Market Outlook and Summary of Opportunities Report). The waste is generated from failed prints and rejected support structures which are common occurrences for personal use. Plastic recycling has become one of the leading discussions of environmental protection and waste management. The 3D market currently does not offer an effective and affordable …

Quality Assurance Of Lightweight Structures Via Phase-Based Motion Estimation, Ikenna E. Ifekaonwu

College of Graduate Studies: Theses & Dissertations

In recent years, lightweight structures have become mature and adopted in various applications. The importance of quality assurance cannot be overemphasized hence extensive research has been conducted to assess the quality of lightweight structures. This study investigates a novel process that exploits motion magnification to investigate the damage characteristics of lightweight mission-critical parts. The goal is to assure the structural integrity of 3D printed structures and composite structures by determining the inherent defects present in the part by exploiting their vibration characteristics. The minuscule vibration of the structure was recorded with the aid of a high-speed digital camera, and the …

Note On The Rate And Energy Efficiency Limits For Additive Manufacturing, Timothy Gutowski, Sheng Jiang, Daniel Cooper, Gero Corman, Michael Hausmann, Jan-Anders Manson, Timo Schudeleit, Konrad Wegener, Matias Sabelle, Jorge Ramos-Grez, Dusan P. Sekulic

Mechanical Engineering Faculty Publications

We review the process rates and energy intensities of various additive processing technologies and focus on recent progress in improving these metrics for laser powder bed fusion processing of metals, and filament and pellet extrusion processing of polymers and composites. Over the last decade, observed progress in raw build rates has been quite substantial, with laser metal processes improving by about 1 order of magnitude, and polymer extrusion processes by more than 2 orders of magnitude. We develop simple heat transfer models that explain these improvements, point to other possible strategies for improvement, and highlight rate limits. We observe a …

The Effect Of Process Parameters And Surface Condition On Bond Strength Between Additively Manufactured Components And Polymer Substrates, Bharat Bhushan Chivukula

Graduate Theses and Dissertations

Additive patching is a process in which printers with multiple axes deposit molten material onto a pre-defined surface to form a bond. Studying the effect of surface roughness and process parameters selected for printing auxiliary part on the bond helps in improving the strength of the final component. Particularly, the influence of surface roughness, as established by adhesion theory, has not been evaluated in the framework of additive manufacturing (AM). A full factorial design of experiments with five replications was conducted on two levels and three factors, viz., layer thickness, surface roughness, and raster angle to examine the underlying effects …

Study Of Oxidative-Crosslink Reaction In Polyphenyl Sulfide (Pps) / Carbon Fiber And Its Influence In Additive Manufacturing, Dong Hee Kim, Eduardo Barocio, Bastian Brenken, Anthony Favaloro, Byron Pipes

The Summer Undergraduate Research Fellowship (SURF) Symposium

Ever since its development in 1980s, Fused Filament Fabrication (FFF) has been an attractive additive manufacturing technology due to its flexibility to create intricate shapes at lower costs and faster manufacturing process than subtractive techniques. These advantages make FFF suitable for printing molds for use in traditional composites manufacturing processes. Combining FFF with high-temperature thermoplastic composites enables producing molds that not only sustain autoclave conditions but also have low coefficient of thermal expansion (CTE). A semi-crystalline polymer, Poly-phenylene Sulfide (PPS), with 50% by weight of carbon fiber is used as feedstock material for FFF. Nonetheless, PPS is sensitive to undergo …