Interlayered composites with three types of cores were fabricated and tested. Quasi-static penetration tests (QSPTs), bending tests, and impact tests were conducted on the fabricated composites with carbon fiber epoxy laminate facings. Penetration test procedures were carried out until the composite was perforated and completely punctured. A 9 mm diameter rounded-tip punch was used; the diameter of the support hole was 45 mm. To determine the mechanical properties in the bending tests, three-point bending was carried out at a speed of 2 mm/min. Impact tests were also carried out using a Charpy impact test and a hammer with an energy of 2 J. Our findings indicate that the core material plays a crucial role in determining a composite’s mechanical behavior. Balsa cores offer the best properties in the QSPT test and bending strength and stiffness (57 MPa and 7.4 GPa, respectively), while Rohacell^® cores provide excellent impact resistance (12 kJ/m²). Nomex^® cores demonstrate high bending stiffness (5.3 GPa) but perform worse than Balsa. The choice of core material is application-dependent; Balsa cores are optimal for bending and point loads, and Rohacell^® cores are optimal for impact-dominated scenarios.

The mathematical model of the polymer plasticization in the reciprocating screw injection moulding machine is presented in this paper. Methods of calculation of the most important flow characteristics, such as the solid bed profile, the pressure and temperature profiles, the mass flow rate, the power demand, the screw torque and the energy consumption were analysed. According to the mathematical model, a computer program was developed. Based on the computer program, simulation studies of the injection moulding process were conducted. Thereafter, the experimental studies, evaluating the theoretical model from the accuracy and usefulness point of view, were carried out. Important output quantities, such as the temperature and pressure profiles, the power demand by the screw, the torque on the screw and the screw rotation time were measured. The studies were performed on a specially made research office. The simulation results were compared with the experimental data measured for the most popular polymers and different operating parameters of the injection machine. The experimental studies have indicated the need to introduce some corrections to the mathematical model. Several modifications have been made to the model, mainly related to the methods of stress determining in the polymer layer. Finally, the output characteristics of the plasticization process in the injection moulding are now correctly determined by the model with an average error less than 10%.

This article describes an innovative thermal insulation barrier in the form of a sandwich panel manufactured using 3D FDM printing technology. The internal structure (core structure) of the barrier is based on the Kelvin foam model. This paper presents the influence of the parameters (the height h and the porosity P of a single core cell) of the barrier on its properties (thermal conductivity, thermal resistance, compressive strength, and quasi-static indentation strength). The dominant influence of the porosity of the structure on the determined physical properties of the fabricated samples was demonstrated. The best insulation results were obtained for single-layer composites with a cell height of 4 mm and a porosity of 90%, where the thermal conductivity coefficient was 0.038 W/(m·K) and the thermal resistance 0.537 (m²·K)/W. In contrast, the best compressive strength properties were obtained for the 50% porosity samples and amounted to about 350 MPa, while the moduli for the 90% porosity samples were 14 times lower and amounted to about 26 MPa. The porosity (P) of the composite structure also had a significant effect on the punch shear strength of the samples produced, and the values obtained for the 90% porosity samples did not exceed 1 MPa. In conclusion, the test showed that the resulting 3D cellular composites offer an innovative and environmentally friendly approach to thermal insulation.

Polypropylene (PP) exhibits high flammability (LOI ≈ 17.5%), which limits its industrial applications. Previous studies have primarily focused on the flame-retardant mechanisms of intumescent flame-retardant (IFR) systems, while less attention has been given to the role of inorganic synergistic additives in balancing flame retardancy with mechanical performance—an aspect crucial for commercial applications This study investigated the effect of small additions of zinc oxide (ZnO) and manganese oxide (MnO) on the flame-retardant, mechanical, and thermal properties of PP/IFR (APP + PER) composites. The oxide content was varied between 0 and 2 wt.%. LOI and UL-94 tests showed that as little as 0.25 wt.% increased LOI to 30% and enabled all materials to achieve a UL-94 V-0 classification. The highest performance was observed for ZnO (LOI = 43.7% at 1.5 wt.%), while MnO induced a linear increase up to 38.6% at 2 wt.%. SEM analysis confirmed the formation of a compact, foamed char layer. Mechanical testing revealed improved stiffness (~15%) and flexural strength (~20%), with unchanged tensile strength but reduced impact strength (−50% for ZnO, −30% for MnO). The HDT increased from 55 °C to 65 °C. These findings demonstrate that small amounts of ZnO and MnO act as effective and economically viable IFR synergists in PP composites.