Injection moulding (IM) is a manufacturing technique used to produce intricately detailed plastic components with various surface finishes, enabling the production of high-tolerance functional parts at scale. Conversely, stereolithography (SLA) three-dimensional (3D) printing offers an alternative method for fabricating moulds with shorter lead times and reduced costs compared to conventional manufacturing. However, fabrication in a layer-by-layer fashion results in anisotropic properties and noticeable layer lines, known as the stair-step effect. This study investigates post-processing techniques for plaques with contrasting stair-step effects fabricated from commercially available SLA high-temperature resin, aiming to assess their suitability for IM applications. The results reveal that annealing significantly enhances part hardness and heat deflection temperature (HDT), albeit with a trade-off involving reduced flexural strength. Experimental findings indicate that the optimal stage for abrasive surface treatment is after UV curing and before annealing. Plaques exhibiting contrasting stair-step effects are characterized and evaluated for weight loss, dimensional accuracy, and surface roughness. The results demonstrate that abrasive blasting effectively removes the stair-step effect without compromising geometry while achieving polished surface finishes with roughness average (RA) values of 0.1 μm through sanding. Overall, a combination of abrasive blasting and sanding proves capable of precisely defining surface roughness without significant geometry loss, offering a viable approach to achieving traditional IM finishes suitable for both functional and aesthetic purposes.

This study explores the mechanical performance of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) filaments fabricated using fused filament fabrication (FFF), Arburg plastic freeforming (APF), and injection moulding (IM). A series of controlled experiments, including differential scanning calorimetry (DSC), scanning electron microscopy (SEM), dynamic mechanical thermal analysis (DMA), and mechanical tests, were conducted to evaluate the material’s mechanical, thermal, and chemical properties. The results highlight the influence of process parameters and material choice on the mechanical properties of PC/ABS components. The FFF samples exhibited the highest impact strength (up to 28.82 kJ/m²), attributed to porosity acting as a stress absorber under impact load. However, this same porosity led to a 9.14% and 19.27% reduction in flexural and tensile strength, respectively, compared to the APF samples, where stress concentration effects were more pronounced under flexural loads. APF’s mechanical properties were comparable to those of IM, with the process achieving the highest tensile strength, highlighting its potential for producing robust PC/ABS samples. This study aims to provide valuable insight into the selection of additive manufacturing (AM) processes for PC/ABS components.

Following the formulation development from a previous study utilising N-vinylcaprolactam (NVCL) and N-isopropylacrylamide (NIPAm) as monomers, poly(ethylene glycol) dimethacrylate (PEGDMA) as a chemical crosslinker, and Irgacure 2959 as photoinitiator, nanoclay (NC) is now incorporated into the selected formulation for enhanced mechanical performance and swelling ability. In this research, two types of NC, hydrophilic bentonite nanoclay (NCB) and surface-modified nanoclay (NCSM) of several percentages, were included in the formulation. The prepared mixtures were photopolymerised, and the fabricated gels were characterised through Fourier transform infrared spectroscopy (FTIR), cloud-point measurements, ultraviolet (UV) spectroscopy, pulsatile swelling, rheological analysis, and scanning electron microscopy (SEM). Furthermore, the effect of swelling temperature, NC types, and NC concentration on the hydrogels’ swelling ratio was studied through a full-factorial design of experiment (DOE). The successful photopolymerised NC-incorporated NVCL-NIPAm hydrogels retained the same lower critical solution temperature (LCST) as previously. Rheological analysis and SEM described the improved mechanical strength and polymer orientation of gels with any NCB percentage and low NCSM percentage. Finally, the temperature displayed the most significant effect on the hydrogels’ swelling ability, followed by the NC types and NC concentration. Introducing NC to hydrogels could potentially make them suitable for applications that require good mechanical performance.

Poly (N-vinylcaprolactam) (PNVCL) and poly (N-isopropylacrylamide) (PNIPAm) are two popular negatively temperature-responsive hydrogels, due to their biocompatibility, softness, hydrophilicity, superabsorbency, viscoelasticity, and near-physiological lower critical solution temperature (LCST). These characteristics make them ideal for biomedical applications. When combined with other materials, hydrogel expansion induces the morphing of the assembly due to internal stress differences. Our recent developments in NVCL hydrogel, enhanced by nanoclay incorporation, have driven us to the creation of a bilayer structure to study its shapeshifting response across various temperatures. This study focused on the bending behaviour of bilayer samples composed of an active hydrogel layer and a passive non-swellable layer. Using photopolymerisation, circular discs and rectangular bilayer samples of varying sizes were fabricated. Homogeneous circular samples demonstrated that hydrogel density increased proportionally with temperature, with the swelling ratio exhibiting two distinct rates of change below and above its LCST. In bilayer samples, the volume of the passive layer influenced bending, and its optimal volume was identified. The investigation revealed that geometry affected the overall bending effect due to changes in the passive layer stiffness. Lastly, a temperature-responsive gripper capable of picking up objects several times its own weight was demonstrated, highlighting the potential of NVCL hydrogels as bioactuators for minimally invasive surgery.

This study investigates the effect of extrusion screw speed and carbon nanotube (CNT) concentration on the thermal, mechanical, and electromagnetic interference shielding effectiveness (EMI SE) properties of Polycarbonate (PC)/acrylonitrile-butadiene-styrene (ABS) and its polymer nanocomposites (PNCs) by means of design of experiments (DoE) approach. A masterbatch method was employed to obtain the best dispersion of the CNTs throughout the polymer matrix. This study evaluates the thermo-mechanical characterisation of the polymers and PNCs at varying screw speeds to assess filler matrix bonding. The results highlight that CNT concentration has a significant effect on all mechanical properties, while screw speed only affects the Charpy impact strength and flexural properties of the samples. Compounding at 200 rpm has the best flexural and tensile strength, which is attributed to the best filler matrix bonding (highest storage modulus) of the PNCs. The best EMI SE results were obtained at 10 wt.% CNTs. This research contributes valuable insights into the effect of CNT concentration and extrusion screw speed on the mechanical, thermal and EMI SE properties of PC/ABS and its PNCs.