Tire wear particles (TWPs) are one of the environment's most important emission sources of microplastics. In this work, chemical identification of these particles was carried out in highway stormwater runoff through cross-validation techniques for the first time. Optimization of a pre-treatment method (i.e., extraction and purification) was provided to extract TWPs, avoiding their degradation and denaturation, to prevent getting low recognizable identification and consequently underestimates in the quantification. Specific markers were used for TWPs identification comparing real stormwater samples and reference materials via FTIR-ATR, Micro-FTIR, and Pyrolysis-gas-chromatography-mass spectrometry (Pyr-GC/MS). Quantification of TWPs was carried out via Micro-FTIR (microscopic counting); the abundance ranged from 220,371 ± 651 TWPs/L to 358,915 ± 831 TWPs/L, while the higher mass was 39,6 ± 9 mg TWPs/L and the lowest 31,0 ± 8 mg TWPs/L. Most of the TWPs analyzed were less than 100 μm in size. The sizes were also confirmed using a scanning electron microscope (SEM), including the presence of potential nano TWPs in the samples. Elemental analysis via SEM supported that a complex mixture of heterogeneous composition characterizes these particles by agglomerating organic and inorganic particles that could derive from brake and road wear, road pavement, road dust, asphalts, and construction road work. Due to the analytical lack of knowledge about TWPs chemical identification and quantification in scientific literature, this study significantly contributes to providing a novel pre-treatment and analytical methodology for these emerging contaminants in highway stormwater runoff. The results of this study highlight the uttermost necessity to employ cross-validation techniques, i.e., FTIR-ATR, Micro-FTIR, Pyr-GC/MS, and SEM for the TWPs identification and quantification in the real environmental samples.

Bio-composites have been formulated by exploiting post-industrial PLA derived from thin film production and silver skin, a by-product of the coffee’s roasting process. The mix design for the compounds exploits the effects of regrading and toughening agents. The mechanical properties of the materials have been investigated as well as the thermal and physical ones. The recycled material mixed with the regrading additive shows good mechanical properties. The filler addition increases the elastic modulus of PLA up to a 20% but decreases the mechanical properties (about 20% on tensile strength), leading to a brittle behavior (minus 35% of impact strength). The use of a toughening agent restores the plastic deformation ability of the matrix.

Arburg plastic freeforming (APF) technology allows for fabricating patient-specific implants (PSIs) in a hospital environment using medical-grade thermoplastic polymers. Among these materials, poly(carbonate-urethane) (PCU) is of great relevance since it is characterised by excellent biocompatibility. This study explores the opportunity to realise a patient-specific cranial plate via APF. First, a Finite Element model (FEM) of the implant under compressive loads is developed and validated using a quasi-isotropic material. Then, this model is used for Finite Element Analysis (FEA) considering Technical Datasheet (TDS) material properties and those measured on 3D-printed specimens, by Three-Point Bending (TPB) tests. Finally, a PCU PSI is fabricated through APF and tested under static loads to validate the consistency of the numerical results. Considering TDS properties, the FEA results indicate that PCU can be used for the manufacturing of this device. Nonetheless, the TPB tests show that the material suffers from a loss of mechanical properties. Using these properties, the displacements calculated via FEA exceed the admissible values for the application. A further decrease in stiffness is observed in the manufactured plate. Overall, findings suggest that PCU can be a viable material to be printed by APF technology for fabricating craniofacial PSIs, with the advantage of minor stress concentration in critical points of the implant if compared with polyetheretheretherketone (PEEK). However, further studies are necessary to effectively represent the effects of 3D printing in the FEMs used for structural validation and design optimisation.

The formulation of composites reinforced with shredded epoxy-carbon fibers wastes is investigated. Poly (buthylene terephthalate) PBT was selected as the matrix for the composites. In order to increase the interaction between the epoxy resin still coating the carbon fibers and the PBT matrix, polycarbonate (PC) was added either to the matrix formulation or as a waste coating. The flexural strength, impact strength, and dynamic-mechanical analysis of the new composites was investigated, as well as their microstructure by scanning electron microscopy. Experimental results show that the recycled fibers can be dispersed in both pure PBT and in its blend, enhancing the mechanical properties of the composites. An increase in the investigated properties is found specifically in the elastic modulus below 50 °C and in the impact strength. The extent of the increase depends on the obtained microstructure.

Lightweight design is often assumed to be the leading strategy to improve the sustainability of parts produced by additive manufacturing. The present study confutes such an assumption by a cradle-to-gate life cycle assessment of different lightweight strategies applied to a specific case study in the medical field. In particular, a patient-specific finger splint made of polyamide is redesigned by means of generative design, topology optimization and lattice structures. The analysis investigates two markedly different deposition processes, namely Arburg plastic freeforming and fused filament fabrication. The former is carried out on an industrial-grade machine, while a desktop printer is used for the latter. This allows for observing the impact of the redesign in two quite distinct scenarios. Findings demonstrate that, since environmental impacts are mainly driven by building time, the adoption of automated design algorithms can be detrimental to the sustainability of the process. On the other hand, relevant benefits on environmental impacts were achieved by reducing the infill percentage of parts. The results of this work highlight the most relevant aspects which must be considered to limit environmental impacts when designing parts for deposition-based additive manufacturing. This information can be used by designers to drive weight reduction towards sustainability.