Co-extrusion is a widely used processing technique for combining various polymers with different properties into a tailored multilayer product. Individual melt streams are combined in a die to form the desired shape. Under certain conditions, interfacial flow instabilities are observed; however, fundamental knowledge about their onset and about critical conditions in science and industry is scarce. Since reliable identification of interfacial co-extrusion flow instabilities is essential for successful operation, this work presents in situ measurement approaches using a novel co-extrusion demonstrator die, which is fed by two separate melt streams that form a well-controlled two-layer co-extrusion polymer melt flow. An interchangeable cover allows installation of an optical coherence tomography (OCT) sensor and of an ultrasonic (US) measurement system, where the former requires an optical window and the latter good direct coupling with the cover for assessment of the flow situation. The feasibility of both approaches was proven for a material combination that is typically found in multilayer packaging applications. Based on the measurement signals, various parameters are proposed for distinguishing reliably between stable and unstable flow conditions in both measurement systems. The approaches presented are well suited to monitoring for and systematically investigating co-extrusion flow instabilities and, thus, contribute to improving the fundamental knowledge about instability onset and critical conditions.

A rugged handheld sensor for rapid in-field classification of cannabis samples based on their THC content using ultra-compact near-infrared spectrometer technology is presented. The device is designed for use by the Austrian authorities to discriminate between legal and illegal cannabis samples directly at the place of intervention. Hence, the sensor allows direct measurement through commonly encountered transparent plastic packaging made from polypropylene or polyethylene without any sample preparation. The measurement time is below 20 s. Measured spectral data are evaluated using partial least squares discriminant analysis directly on the device’s hardware, eliminating the need for internet connectivity for cloud computing. The classification result is visually indicated directly on the sensor via a colored LED. Validation of the sensor is performed on an independent data set acquired by non-expert users after a short introduction. Despite the challenging setting, the achieved classification accuracy is higher than 80%. Therefore, the handheld sensor has the potential to reduce the number of unnecessarily confiscated legal cannabis samples, which would lead to significant monetary savings for the authorities.

The durability of piezoresistive sensor materials is a core prerequisite for their implementation in structural health monitoring systems. In this work, three piezoresistive materials were subjected to extensive cyclic tensile loadings, and their behaviour was analysed before, after, and during testing. To this end, aluminium specimens were coated with three different industry-grade lacquers, and then piezoresistive materials were applied onto each specimen. Sensors made from carbon black displayed excellent linearity even after tensile loading cycles ($R^2>0.88$). A decline in linearity of all sensors based on carbon allotropes was discovered, whereas the polymer-based sensors improved. Furthermore, their adhesion to the substrate is of great importance. Good adhesion ensures the strains in the underlying structure are correctly transmitted into the sensor materials. Based on contact angle measurements of liquids on sensor materials and on lacquers, their work of adhesion was determined. The findings were verified by tape adhesion tests.

When overmoulding optoelectronic devices with optical elements, precise alignment of the overmoulded part and the mould is of great importance. However, mould-integrated positioning sensors and actuators are not yet available as standard components. As a solution, we present a mould-integrated optical coherence tomography (OCT) device that is combined with a piezo-driven mechatronic actuator, which is capable of performing the necessary displacement correction. Because of the complex geometric structure optoelectronic devices may have, a 3D imaging method was preferable, so OCT was chosen. It is shown that the overall concept leads to sufficient alignment accuracy and, apart from compensating for the in-plane position error, provides valuable additional information about the sample both before and after the injection process. The increased alignment accuracy leads to better energy efficiency, improved overall performance and less scrap parts, and thus even a zero-waste production process might be feasible.