Sesame oil cakes (SOC) produced during sesame oil production can be classified as plant residues. This study aims to use SOC as a composite material for injection molding. A biocomposite containing polypropylene (PP) and SOC, namely PP/SOC, was developed and its mechanical properties were evaluated. PP/SOC is largely divided into Homo-PP/SOC (HPS) based on Homo-PP and Block-PP/SOC (BPS) based on block-PP. The specimens containing 0–50 wt% SOC were prepared through extrusion and injection molding. As a result of the evaluation, SOC acted as a reinforcement in the matrix, and HPS and BPS showed improved flexural modulus by 36.4% and 37.3% compared to the neat PP, respectively. Tensile strength, on the other hand, decreased by 58% and 55.1%, respectively. To analyze the cause of this, cross-section observation was conducted through scanning electron microscope (SEM), and phase separation and voids were confirmed to be the cause of this. Impact strength of PP/SOC tended to vary depending on the type of matrix. HPS increased by 30.9% compared to neat PP, and BPS decreased by 25%. This tendency difference appears to be the result of SOC inhibiting crystallization of PP, and it has been confirmed through x ray diffraction (XRD) and differential scanning calorimetry (DSC) analysis. Moreover, PP/SOC can be manufactured at a low cost and is environmentally friendly because it utilizes SOC, a plant residue. It can also be applied to commercial products, such as food packaging, owing to its good moldability and improved mechanical properties.

In this study, the vibration and sound response characteristics of composites produced via injection molding applied with a microcellular foaming process (MCPs) were improved. The study was conducted using PA6 and glass fiber composites, which are representative thermoplastic engineering plastics. Two types of specimens were used: a plate specimen to confirm the basic sound and vibration characteristics, and a large roof-rack specimen from an actual vehicle with a complex shape. The frequency response function curve was calculated by conducting an impact test, and natural frequency and damping ratio were measured based on the curve. The results confirmed that, in the case of a specimen manufactured through the injection molding process to which MCPs were applied, the natural frequency was lowered, and the damping ratio decreased. The degree of change in the natural frequency and damping ratio was confirmed. To determine the cause of the change in the natural frequency and damping ratio, the mode shape at the natural frequency of each specimen was measured and the relationship was confirmed by measuring the density and the elastic modulus of the composite. In addition, the usability of the specimens to which MCPs were applied was verified by conducting impact strength and tensile strength tests.

Ceramics are non-metallic inorganic materials fabricated from natural or high-purity raw materials through heating and cooling processes. Urethane is a three-dimensional plastic with both elasticity and chemical resistance; moreover, it is used as a rubber substitute. The use of both materials in various applications is gradually increasing. However, as ceramics and urethane have distinctly different properties, this prompted questions regarding the properties of a material that is fabricated using both materials. Therefore, we studied the characteristics of a composite material fabricated through physical foaming using a batch process. The process was conducted with gas saturation, foaming, cooling, and curing. When a specimen of 2 mm thickness was saturated in 5 MPa of CO₂ for 2 h, the solubility was 6.43%; when foaming was carried out at a temperature of 150 °C in boiled glycerin, the foaming ratio, cell size, cell density, and void fraction were found to be 43.62%, 24.40 µm, 9.1 × 10⁷ cells/cm², and 22.11%, respectively. Furthermore, the volume increased by 102.96%, color changed from dark to light gray, hardness decreased by 24%, thermal diffusivity increased by 0.046 mm²/s at 175 °C, and friction coefficient decreased to 0.203. Thus, the microcellular foamed ceramic urethane exhibits a larger volume, lighter weight, and improved thermal conductivity and friction coefficient.

Injection research using aluminum flakes has been conducted to realize metallic textures on the surface of plastic products. Several studies have focused on the effect of the orientation and quality of the flakes when using conventional injection molding methods; however, limited studies have focused on the foam injection molding method. In this study, we examined the orientation of aluminum flakes through foam injection with an inert gas and observed the changes in texture using a spectrophotometer and a gloss meter. The mechanical properties were also studied because the rigidity of the product, which is affected by the weight reduction that occurs during foaming, is an important factor. The results demonstrate that under foam injection molding, reflectance and gloss increased by 6% and 7 GU, respectively, compared to those obtained using conventional injection molding; furthermore, impact strength and flexural modulus increased by 62% and 15%, respectively. The results of this research can be applied to incorporate esthetic improvements to products and to develop functional parts.