The growing concern with the environmental impacts of disposable products has placed an emphasis on ensuring the sustainability of material systems. A shift in the selection of material can decrease the negative effects of disposable products. One class of materials with good credentials is biocomposite materials, a material partly consisting of biodegradable products. In this thesis project a compression molding machine suitable for the pressing of biocomposite materials are developed for the start-up Trash to Gold. The start up is in a early process of developing compression molding machine. As of now they use a modified workshop press to test out the pressing of to-go coffee cups made out of biodegradable a biocomposite material partly consisting of coffee grounds. The current press is not optimised for their expected customer group and it is therefore appropriate to develop a new one. The aim of this thesis project is to assist Trash to Gold in their development of a compression molding machine, suitable for upcycling biodegradable waste into disposable products. The objective of this thesis project is to develop a concept of a compression molding machine that can be used to print to-go coffee cups partly made of coffee grounds. The concept to be developed will be for a press that weighs less and has smaller dimensions than the current one to suit the target group. The product development methodology of the project is based on Ulrich and Eppinger’s book ”Product Design and Development”. Some of the approaches used from book are modified for better application on the project. The project also includes digital and theoretical tools to determine if the concept can withstand the pressure generated when the machine is in use. The result of the thesis project is a concept of a compression molding machine that meet requirements given by the start up. Suitable parts for the basic structure of the compression molding machine is presented such as how the pressing function will occur and the outer frame with where the different components will sit. The resulting concept is smaller and more light weight compared to the current machine. / Den växande oron för negativa effekter engångsprodukter har på miljön har lett till ett ökat intresse att säkerställa materialsystemens hållbarhet. En förändring av materialvalet fÅNor produkterna kan minska dessa negativa effekterna. En materialklass som hade kunnat minska de negativa effekterna är biokomposita material. Biokomposit material är ett material som delvis består av biologiskt nedbrytbara produkter. I detta examensarbete utvecklas en formpressningssmaskin anpassad för formpressning av biokomposita material. Projektet görs på uppdrag av startup-företaget Trash to Gold. Företaget håller på att utveckla en formpressningsmaskin och använder just nu en modifierad verkstadspress för att testa tillverkningen av engångskaffemuggar som delvis består av kaffesump. Den nuvarande pressen är inte anpassad för den förväntade kundgruppen och det är därför l'mpligt att utveckla en ny. Syftet bakom detta examensarbete är att hjälpa Trash to Gold att utveckla en formpressningsmaskin som är anpassad för återanvändningen av bionedbrytbara restprodukter till engångsartiklar. Målet med det här examensarbetet är att utveckla ett koncept av en formpressningsmaskin som kan användas för att formpressa engångskaffemuggar delvis bestående av kaffesump. Konceptet som tas fram ska vara för en press som väger mindre och har mindre dimensioner än den nuvarande för att passa målgruppen. Arbetets produktutvecklingsmetodik är baserad på Ulrich och Eppingers (U&E) bok ”Product design and Development”. Exempel på metoder som använts är identifiering av kundbehov, produktspekification, konceptgeneration, extern- och intern undersökning samt olika poängsättningsmetoder. Arbetet omfattar också teoretiska modeller och verktyg för att räkna på konceptets hållfasthet, materialval och val av komponenter. Resultatet av examensarbetet är ett koncept för en formpressningsmaskin som uppfyller de krav som ställts av start up-företaget. Lämpliga delar för grundkonstruktionen av formpressningsmaskinen presenteras. Till dessa hör vad som ska ge upphov till pressfunktionen samt den yttre ramen där de olika komponenterna kommer att sitta. Det resulterande konceptet väger mindre och har mindre dimensioner jämfört med den nuvarande maskinen.

The preparation of polymeric hybrid composite consisting of organic and inorganic fillers is of interest for industries like automotive, construction and packaging. In order to understand and predict the physical and chemical properties of these hybrid composites, it is necessary to fully understand the nature and properties of the employed fillers. In this study, the preparation of polypropylene hybrid composite consisting of wheat straw and clay was investigated. A detailed study was performed on wheat straw from South Western Ontario region. The effect of grinding the straw and compounding it with polypropylene was investigated. Experiments were carried out to identify the thermal stability of the ground wheat straw with respect to their size and composition. It was important to identify a correlation between these properties in order to minimize the straw degradation by processing and also to improve the final properties of the hybrid composite. The composite samples were prepared through melt blending method using a co-rotating twin-screw extruder. Sample test bars were prepared by injection moulding. The composition of the constituents of the hybrid composite; percentages of wheat straw, clay and coupling agent, were varied in order to investigate their influence on thermal stability, water resistance and mechanical properties. The results of the study indicated that grinding the wheat straw with a hammer mill produced particles with different sizes and shapes. It was found that through the grinding system all particles, regardless of their size, had a multi-layered structure similar to the plant structure. Further hammer milling did not produce plant particles with long aspect ratios that would be expected in a defibrillation process. Analysis of the chemical composition of wheat straw particles of different sizes and shapes was used to measure the ratio of hemicelluloses: lignin and the ash content. It was found that the large particles contained more amount of lignin whereas smaller particles had larger amount of ash content. The thermal stability of the particles was found to be a function of particle size rather than the lignin content. Particle size analysis on the wheat straw particles after the extrusion process indicated a reduction in the particle length and aspect ratio. The thermal stability of the composites was found to be enhanced by the addition of clay particles at higher temperature and the addition of coupling agent at lower temperatures. Increasing the amount of wheat straw and clay content increased the flexural modulus and reduced the resistance for water absorption. Increasing the amount of coupling agent also increased the flexural modulus and resistance for water absorption. The morphological study by scanning electron microscopy revealed that coupling agent increased the interfacial interaction between the particles and the polymer matrix.

The preparation of polymeric hybrid composite consisting of organic and inorganic fillers is of interest for industries like automotive, construction and packaging. In order to understand and predict the physical and chemical properties of these hybrid composites, it is necessary to fully understand the nature and properties of the employed fillers. In this study, the preparation of polypropylene hybrid composite consisting of wheat straw and clay was investigated. A detailed study was performed on wheat straw from South Western Ontario region. The effect of grinding the straw and compounding it with polypropylene was investigated. Experiments were carried out to identify the thermal stability of the ground wheat straw with respect to their size and composition. It was important to identify a correlation between these properties in order to minimize the straw degradation by processing and also to improve the final properties of the hybrid composite. The composite samples were prepared through melt blending method using a co-rotating twin-screw extruder. Sample test bars were prepared by injection moulding. The composition of the constituents of the hybrid composite; percentages of wheat straw, clay and coupling agent, were varied in order to investigate their influence on thermal stability, water resistance and mechanical properties. The results of the study indicated that grinding the wheat straw with a hammer mill produced particles with different sizes and shapes. It was found that through the grinding system all particles, regardless of their size, had a multi-layered structure similar to the plant structure. Further hammer milling did not produce plant particles with long aspect ratios that would be expected in a defibrillation process. Analysis of the chemical composition of wheat straw particles of different sizes and shapes was used to measure the ratio of hemicelluloses: lignin and the ash content. It was found that the large particles contained more amount of lignin whereas smaller particles had larger amount of ash content. The thermal stability of the particles was found to be a function of particle size rather than the lignin content. Particle size analysis on the wheat straw particles after the extrusion process indicated a reduction in the particle length and aspect ratio. The thermal stability of the composites was found to be enhanced by the addition of clay particles at higher temperature and the addition of coupling agent at lower temperatures. Increasing the amount of wheat straw and clay content increased the flexural modulus and reduced the resistance for water absorption. Increasing the amount of coupling agent also increased the flexural modulus and resistance for water absorption. The morphological study by scanning electron microscopy revealed that coupling agent increased the interfacial interaction between the particles and the polymer matrix.

Natural fiber-reinforced composites are now finding extensive uses in various fields from household articles to automobiles. These composites can score high compared to common synthetic fiber-based composites, notably glass fiber-reinforced composites, in areas such as occupational safety and health, and impact on environment. The current research work is motivated by the need for exploring jute fibers as replacement for glass fibers for various engineering design applications including more demanding impact protection applications as in automotive body structures. In the current work, detailed mechanical characterization of jute-polyester (JP) composite laminates till failure has been carried out for tensile, compressive and flexural loads by varying volume fraction of jute fibers. The effect of fiber volume fraction on mechanical properties is shown. Because of the potency of closed thin-walled components as structural energy-absorbers, a comprehensive experimental study has been performed, for the first time, comparing the behaviors of various geometric sections of JP and glass-polyester (GP) composite tubes under axial quasi-static and low velocity impact loading. Additionally, for jute-reinforced plastic panels to be feasible solutions for applications such as automotive interior trim panels, laminates made of such materials should have adequate perforation resistance. Thus, a detailed comparative study has been carried out for assessing the performance of JP laminates vis-a-vis GP plates under low velocity impact perforation conditions. As high-end product design is heavily driven by CAE (Computer-Aided Engineering), the current research work has also focused on the challenging task of developing reliable modeling procedures for explicit finite element analysis using LS-DYNA for predicting load-displacement responses and failures of JP composites under quasi-static and impact loading conditions. In order to extend the applications of JP composites to structurally demanding applications, hybrid laminates made of jute-steel composites and jute with nanoclay-reinforced polyester have been investigated and the considerable enhancement of mechanical properties due to hybridization is shown. Furthermore, a comprehensive study has been conducted on the behavior of JP laminates for varying degrees of moisture content until saturation, and the efficacy of hybrid laminates in this context has been shown.

Le travail présenté porte sur la rhéologie, la mise en forme et la caractérisation de matériaux biocomposites de nouvelles générations pour des applications orthopédiques. Dans le cadre de cette étude, des biocomposites poly (D,L-lactide) (PDLLA)/bioverres ont été élaborés par extrusion bivis sous atmosphère inerte. Les bioverres différent par la nature de leur traitement thermique et leur morphologie. La première partie a été consacrée à l’étude de l’état de la dispersion des bioverres dans la matrice polymère. Nous avons montré que l’homogénéité de cette dispersion dépend, d’une part de la structure, de la morphologie, du taux volumique des charges et d’autre part des paramètres du procédé (cisaillement, température,…). Le comportement rhéologique des suspensions a été étudié à l’état fondu ainsi qu’à l’état solide. Un accent particulier a été porté sur l’étude de l’influence du taux des bioverres, de leur taille moyenne et plus particulièrement de leur traitement thermique. Les masses molaires de PDLLA extrait des composites élaborés ont été évaluées par chromatographie d’exclusion stérique (CES). Enfin, la qualité de la dispersion des charges, en termes de distance inter-particulaire et taille moyenne, a été étudiée par microscopie électronique à balayage (MEB) et analyses d’image. Il a été montré que l’utilisation de bioverres non traités thermiquement lors de la mise en forme de composites à haute température provoque la dégradation de la matrice. Aussi, on assiste à une réduction des masses molaires. Les propriétés viscoélastiques et les propriétés mécaniques sont altérées à leur tour. Cette dégradation a été étudiée par spectroscopie infrarouge (IRTF) et par analyse thermogravimétrique (ATG). Les origines et mécanismes sous-jacents de cette dégradation ont été proposés. Il est démontré pour la première fois que la présente dégradation du PDLLA peut être atténuée par l’emploi de différentes charges céramiques à propriétés spécifiques. En outre, l’utilisation de ces bioverres a permis l’obtention d’une dispersion homogène au sein de la matrice. L’analyse des propriétés rhéologiques de tels matériaux et leur modélisation a permis de mettre en évidence les interactions matrice-charges. La deuxième partie de l’étude a porté sur l’élaboration des biocomposites multicouches à gradient de propriétés par coextrusion. Ces multicouches présentent, d’une part, des propriétés variables selon le type de traitement et de composition du bioverre actif. D’autre part, le gradient de propriété a été également réalisé en faisant varier les paramètres expérimentaux relatifs au procédé de coextrusion. Les matériaux finaux, ainsi obtenus, présentent de très bonnes propriétés cohésives avec une bioactivité maîtrisée et contrôlée. / Bioactive and biodegradable composites have gained increasing importance in the orthopedic field as bone replacement materials and as scaffolds for tissue engineering. In this study, biocomposites based on poly(D,L-lactide) (PDLLA) and bioactive glass fillers were prepared by a twin screw extrusion under Argon inert gas with various filler contents, thermal treatments and particle sizes. The processing conditions were monitored to produce composites with well controlled physico-chemical, mechanical and dispersive properties. The aim of the present work is to gain a fundamental understanding of the relationships between structure, processing conditions and final properties of these biocomposites. The dispersion state of fillers was characterized by SEM. It was highlighted that the inclusion of non treated bioglass in PDLLA under elevated temperatures resulted in a decrease of molar mass. This degradation of the matrix leads to a reduction of the viscoelastic and mechanical properties of the composites. The origin and mechanisms of this degradation were probed using a Fourier Transform Infrared (FTIR) spectroscopy. The optimization of their processing allows a better control of this drastic loss of properties. Furthermore, the demonstration had been done that the present degradation of PDLLA matrix can be attenuated using a different glass ceramics with a special size and thermally treated. The rheological behaviour in linear and non linear viscoelasticity of the controlled PDLLA/BG suspensions has been assessed in both solid and molten state. Hence, their experimental rheological behaviour was compared to the theoretical suspension models. Finally, the effects of volume fraction, particle size and thermal treatment on the mechanical properties have been also investigated and discussed. The obtained results corroborate the rheological and physic-chemical ones. Finally, the multilayer structures with various amounts and treatments of BG fillers were obtained by a designed scale lab coextrusion machines. The gradient of properties has been obtained and improved cohesion properties between the neighboring were highlighted. Their bioactivity was finally demonstrated. At last, no residual stress inside the multilayers can be observed. This observation explains the conservation of the initial shape of those implants, without nor deformation neither relaxation, during the simulation of the chirurgical implantation in SBF.