In this paper, nanocomposites based on polypropylene (PP) filled with up to 5 wt.% of multi-walled carbon nanotubes (MWCNTs) were investigated for determining the material property data used in numerical simulation of manufacturing processes such as the injection molding and extrusion. PP/MWCNT nanocomposite pellets were characterized for rheological behavior, crystallinity, specific volume and thermal conductivity, while injection-molded samples were characterized for mechanical and electrical properties. The addition of MWCNTs does not significantly change the melting and crystallization behavior of the PP/MWCNT nanocomposites. The effect of MWCNTs on melt shear viscosity is more pronounced at low shear rates and MWCNT loadings of 1–5 wt.%. However, with the addition of up to 5 wt.% of MWCNTs, the PP/MWCNT nanocomposite still behaves like a non-Newtonian fluid. The specific volume of the PP/MWCNT nanocomposites decreases with increasing MWCNT loading, especially in the MWCNT range of 1–5 wt.%, indicating better dimensional stability. The thermal conductivity, depending on the pressure, MWCNT wt.% and temperature, did not exceed 0.35 W/m·K. The PP/MWCNT nanocomposite is electrical non-conductive up to 3 wt.%, whereas after the percolating path is created, the nanocomposite with 5 wt.% becomes semi-conductive with an electrical conductivity of 10⁻¹ S/m. The tensile modulus, tensile strength and stress at break increase with increasing MWCNT loading, whereas the elongation at break significantly decreases with increasing MWCNT loading. The Cross and modified 2-domain Tait models are suitable for predicting the melt shear viscosity and specific volume as a function of MWCNTs, respectively. These results enable users to integrate the PP/MWCNT nanocomposites into computer aided engineering analysis.

Fused filament fabrication (FFF) has recently emerged as a sustainable digital manufacturing technology to fabricate polymer composite parts with complex structures and minimal waste. However, FFF-printed composite parts frequently exhibit heterogeneous structures with low mechanical properties. To manufacture high-end parts with good mechanical properties, advanced predictive tools are required. In this paper, Artificial Neural Network (ANN) models were developed to evaluate the mechanical properties of 3D-printed polyamide 12 (PA) and carbon fiber (CF) and glass fiber (GF) reinforced PA composites. Tensile samples were fabricated by FFF, considering two input parameters, such as printing orientation and infill density, and tested to determine the mechanical properties. Then, single- and multi-target ANN models were trained using the forward propagation Levenberg–Marquardt algorithm. Post-training performance analysis indicated that the ANN models work efficiently and accurately in predicting Young’s modulus and tensile strength of the 3D-printed PA and fiber-reinforced PA composites, with most relative errors being far less than 5%. In terms of mechanical properties, such as Young’s modulus and tensile strength, the 3D-printed composites outperform the unreinforced PA. Printing PA composites with 0° orientation and 100% infill density results in a maximum increase in Young’s modulus (up to 98% for CF/PA and 32% for GF/PA) and tensile strength (up to 36% for CF/PA and 18% for GF/PA) compared to the unreinforced PA. This study underscores the potential of the ANN models to predict the mechanical properties of 3D-printed parts, enhancing the use of 3D-printed PA composite components in structural applications.

In this paper, the impact of recycling and remanufacturing on the behavior of low-density polyethylene/multi-walled carbon nanotube (LDPE/MWCNT) composites is investigated. LDPE/MWCNT composites with 0.1–5 wt%, previously manufactured by injection molding, were mechanically recycled and remanufactured by injection molding and 3D filament extrusion, and the rheological, electrical, and mechanical properties were analyzed and compared with those of virgin composites under the same conditions. Experimental results demonstrate that the recycled LDPE/MWCNT composites have similar rheological, electrical, and mechanical properties as that of virgin composites, if not better. Therefore, the recycled LDPE/MWCNT composites have a great potential for being used in engineering applications, while reducing the environmental impact.

This paper investigates the rheological, mechanical and electrical properties of a Ethylene-Vinyl Acetate (EVA) polymer filled with 1, 3 and 5 wt.% multi-walled carbon nanotubes (MWCNTs). The melt flow and pressure-volume-Temperature (pvT) behaviors of the EVA/MWCNT composites were investigated using a high-pressure capillary rheometer, while the electro-mechanical response was investigated on injection-molded samples. Rheological experiments showed that the melt shear viscosity of the EVA/MWCNT composite is dependent on nanotube loading and, at high shear rates, the viscosity showed temperature-dependent shear thinning behavior with a flow index n < 0.35. The specific volume of the EVA/MWCNT composite decreased with increasing pressure and MWCNT wt.%. The transition temperature, corresponding to the pvT crystallization, increased linearly with increasing pressure, i.e., about 20 to 30 °C when cooling under pressure. The elastic modulus, tensile strength and stress at break increased with increasing MWCNT wt.%, whereas the strain at break decreased, suggesting the formation of MWCNT secondary agglomerates. The electrical conductivity of the EVA/MWCNT composite increased with increasing MWCNT wt.% and melt temperature, reaching ~10⁻² S/m for the composite containing 5 wt.% MWCNTs. Using the statistical percolation theory, the percolation threshold was estimated at 0.9 wt.% and the critical exponent at 4.95.

Recycling polymer/carbon nanotube (CNT) nanocomposites is not well common, despite a growing interest in using polymer/carbon nanotube (CNT) nanocomposites in industrial applications. In this study, the influence of mechanical recycling on the thermal, rheological, mechanical and electrical behavior of ethylene-vinyl acetate (EVA)/CNT nanocomposites is investigated. EVA/CNT nanocomposite with different amounts of CNTs (1, 3 and 5 wt.%) was subjected to mechanical grinding and reprocessing by injection molding in a close-loop up to three cycles, and the changes induced by mechanical recycling were monitored by Differential Scanning Calorimetry (DSC), capillary rheology, scanning electron microscopy (SEM), electrical resistance and tensile tests. It was found that the EVA/CNT nanocomposites did not exhibit significant changes in thermal and flow behavior due to mechanical recycling and reprocessing. The recycled EVA/CNT nanocomposites retain close to 75% of the original elastic modulus after three recycling cycles and about 80–90% in the tensile strength, depending on the CNT loading. The electrical conductivity of the recycled nanocomposites was about one order of magnitude lower as compared with the virgin nanocomposites, spanning the insulating to semi-conducting range (10⁻⁹ S/m–10⁻² S/m) depending on the CNT loading. With proper control of the injection molding temperature and CNT loading, a balance between the mechanical and electrical properties of the recycled EVA nanocomposites can be reached, showing a potential to be used in practical applications.

In this paper, polypropylene (PP) filled with different levels of multiwalled carbon nanotubes (MWCNTs) manufactured by injection molding was closed-loop recycled in order to investigate the effect of recycling and reprocessing on its rheological, electrical, and mechanical properties. It was found that the PP/MWCNT composites keep the flow performance after mechanical recycling. Moreover, the stress and strain at break increase after one reprocessing cycle (mechanical recycling and injection molding), whereas no statistically significant changes in electrical conductivity, Young's modulus, and tensile strength of the PP/MWCNT composites filled with 1, 3, and 5 wt.% were observed.