The results of computer simulation of thermoforming process made using ANSYS Polyflow software are presented in this paper. The analysis of the wall thickness distribution across an U-shaped thermoformed product manufactured using a positive mould was made. The simulation results were verified using a mould manufactured in a 3D printing process which was Fused Deposition Modelling (FDM) and a poly(ethylene terephthalate) formed sheet. It was proven that the computer simulation and a tool made with a Rapid Tooling technology can be useful for predicting the quality of a thermoformed part, particularly to find the problems with thin-walled areas.

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.

The results of compression "top load" test of an extrusion blow moulded container, performed in ANSYS Mechanical software, were presented. The non-uniform wall thickness of the blown product was considered because the thickness distribution was the result of the first step of the simulation in ANSYS Polyflow - the simulation of the product manufacturing by extrusion blow moulding. The hydrostatic pressure factor was taken into account during the "top load" simulation, because such a test is usually done for filled products. It was found that the biggest stress values occur around the inlet as well as in the side walls of the container.

The injection moulding conditions may change the degree of crystallinity of the plastic to some extent, which affects the mechanical properties such as tensile strength and hardness. Moreover, the cooling conditions of the moulded parts may contribute to changes in their shrinkage. The paper presents the results of determination of the melting enthalpy of a polypropylene. The melting enthalpy ∆ Hm was determined by differential scanning calorimetry. It was found, that the value of the melting enthalpy depends on the physical conditions prevailing during the sample production process, such as the temperature of the liquid material, the cooling rate of the plastic (related to the mould temperature Tm) and the flow rate of the plastic in the mould. The degree of crystallinity of the obtained samples was also determined, which, depending on the measured enthalpy of fusion, influences the degree of structural order of the polymer. Standardized test samples were also analysed in terms of transversal shrinkage and longitudinal shrinkage. The shrinkage of the injection moulded parts results from the change of physical state of plastic during its solidification in the mould.