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Four sustainable materials including a recycled polypropylene blend, polybutylene adipate terephthalate, and two grades of polylactic acid are compared to a reference isotactic polypropylene. Tensile specimens were produced using a two-cavity, hot runner mold with fully automatic cycles per standard industrial practices to investigate the effect of melt temperature, injection velocity, cycle time, and screw speed on the mechanical properties. Multiple regression and principal component analyses were performed for each of the materials. Results indicated that all the materials were readily processed using a hot runner, and the mechanical properties exhibited minimal variation. To the extent that losses in mechanical properties were observed, the results indicated that the losses were correlated with thermal degradation as independently characterized by thermal gravimetric analysis. Such losses can be minimized by reducing melt temperature and cycle time, leading to a reduction of the environmental impact of injection molding processes.
David Kazmer; Davide Masato; Leonardo Piccolo; Kyle Puleo; Joshua Krantz; Varun Venoor; Austin Colon; Justin Limkaichong; Neil Dewar; Denis Babin; Cheryl Sayer. Multivariate Modeling of Mechanical Properties for Hot Runner Molded Bioplastics and a Recycled Polypropylene Blend. Sustainability 2021, 13, 8102 .
AMA StyleDavid Kazmer, Davide Masato, Leonardo Piccolo, Kyle Puleo, Joshua Krantz, Varun Venoor, Austin Colon, Justin Limkaichong, Neil Dewar, Denis Babin, Cheryl Sayer. Multivariate Modeling of Mechanical Properties for Hot Runner Molded Bioplastics and a Recycled Polypropylene Blend. Sustainability. 2021; 13 (14):8102.
Chicago/Turabian StyleDavid Kazmer; Davide Masato; Leonardo Piccolo; Kyle Puleo; Joshua Krantz; Varun Venoor; Austin Colon; Justin Limkaichong; Neil Dewar; Denis Babin; Cheryl Sayer. 2021. "Multivariate Modeling of Mechanical Properties for Hot Runner Molded Bioplastics and a Recycled Polypropylene Blend." Sustainability 13, no. 14: 8102.
The integration of additive manufacturing direct-writing technologies with injection molding provides a novel method to combine functional features into plastic products, and could enable mass-manufacturing of custom-molded plastic parts. In this work, direct-write technology is used to deposit conductive ink traces on the surface of an injection mold. After curing on the mold surface, the printed trace is transferred into the plastic part by exploiting the high temperature and pressure of a thermoplastic polymer melt flow. The transfer of the traces is controlled by interlocking with the polymer system, which creates strong plastic/ink interfacial bonding. The hybrid process chain uses designed mold/ink surface interactions to manufacture stable ink/polymer interfaces. Here, the process chain is proposed and validated through systematic interfacial analysis including feature fidelity, mechanical properties, adhesion, mold topography, surface energy, and hot polymer contact angle.
Dario Loaldi; Leonardo Piccolo; Eric Brown; Guido Tosello; Corey Shemelya; Davide Masato. Hybrid Process Chain for the Integration of Direct Ink Writing and Polymer Injection Molding. Micromachines 2020, 11, 509 .
AMA StyleDario Loaldi, Leonardo Piccolo, Eric Brown, Guido Tosello, Corey Shemelya, Davide Masato. Hybrid Process Chain for the Integration of Direct Ink Writing and Polymer Injection Molding. Micromachines. 2020; 11 (5):509.
Chicago/Turabian StyleDario Loaldi; Leonardo Piccolo; Eric Brown; Guido Tosello; Corey Shemelya; Davide Masato. 2020. "Hybrid Process Chain for the Integration of Direct Ink Writing and Polymer Injection Molding." Micromachines 11, no. 5: 509.
Surface functionalization of plastic parts has been studied and developed for several applications. However, demand for the development of reliable and profitable manufacturing strategies is still high. Here we develop and characterize a new process chain for the versatile and cost-effective production of sub-micron textured plastic parts using laser ablation. The study includes the generation of different sub-micron structures on the surface of a mold using femtosecond laser ablation and vario-thermal micro-injection molding. The manufactured parts and their surfaces are characterized in consideration of polymer replication and wetting behavior. The results of the static contact angle measurements show that replicated Laser-Induced Periodic Surface Structures (LIPSSs) always increase the hydrophobicity of plastic parts. A maximum contact angle increase of 20% was found by optimizing the manufacturing thermal boundary conditions. The wetting behavior is linked to the transition from a Wenzel to Cassie–Baxter state, and is crucial in optimizing the injection molding cycle time.
Leonardo Piccolo; Marco Sorgato; Afif Batal; Stefan Dimov; Giovanni Lucchetta; Davide Masato. Functionalization of Plastic Parts by Replication of Variable Pitch Laser-Induced Periodic Surface Structures. Micromachines 2020, 11, 429 .
AMA StyleLeonardo Piccolo, Marco Sorgato, Afif Batal, Stefan Dimov, Giovanni Lucchetta, Davide Masato. Functionalization of Plastic Parts by Replication of Variable Pitch Laser-Induced Periodic Surface Structures. Micromachines. 2020; 11 (4):429.
Chicago/Turabian StyleLeonardo Piccolo; Marco Sorgato; Afif Batal; Stefan Dimov; Giovanni Lucchetta; Davide Masato. 2020. "Functionalization of Plastic Parts by Replication of Variable Pitch Laser-Induced Periodic Surface Structures." Micromachines 11, no. 4: 429.