Yes / Industry-standard quality management systems such as Six Sigma and emerging Industry 4.0 compliant production processes demonstrate the importance of in-line condition monitoring of manufacturing methods for achieving the highest levels of product quality. Measurement data collected as the process is running can inform the operator about unexpected changes in machine operation or raw materials that could negatively impact production; and offer an opportunity for a process control intervention to stabilise production. However, micro-manufacturing production lines can pose a challenging environment for deploying such systems, since processing events can occur extremely rapidly and in harsh environments. Moreover, the small scale of micro-nano featured components can make sensor installation even more problematic. Recently, ultrasonic micromoulding has drawn attention in niche markets due to its unique advantages for processing thermoplastics as a new micro-manufacturing technology. The process differs from conventional moulding significantly by eliminating the need for a plasticising screw and using direct application of ultrasonic energy to melt the polymer. This offers numerous benefits such as decrease in energy usage, moulding at lower pressures, easier cleaning, and reduced material residence times, the latter which could be beneficial for pharma-grade polymers or polymers with active ingredients. However, very little work has been reported attempting to monitor the process using in-line measurements. This work aims to evaluate the characteristics of the ultrasonic micromoulding process for microinjection moulding of a microneedle array using a range of sensor technologies including: data recorded by the machine controller; a high-speed thermal camera and a cavity pressure transducer. The data has captured the highly dynamic process environment with a high degree of accuracy. The relationship between the process data and dimensional quality of the ultrasonically micromoulded products has been quantified and subsequently implemented as a cost-effective in-line quality assurance method. / Horizon 2020, the EU Framework Programme for Research and Innovation (Project ID: 674801). This research has also received funding and support from two other Horizon 2020 projects: HIMALAIA (Grant agreement No. 766871) and Laser4Fun (GA no. 675063)

This research investigates formulation, compounding and thin-wall injection moulding of Polypropylene/clay nanocomposites (PPCNs) prepared using conventional melt-state processes. An independent study on single screw extrusion dynamics using Design of Experiments (DoE) was performed first. Then the optimum formulation of PPCNs and compounding conditions were determined using this strategy. The outcomes from the DoE study were then applied to produce PPCN compounds for the subsequent study of thin-wall injection moulding, for which a novel four-cavity injection moulding system was designed using CAD software and a new moulding tool was constructed based upon this design. Subsequently, the effects of moulding conditions, nanoclay concentration and wall thickness on the injection moulded PPCN parts were investigated. Moreover, simulation of the injection moulding process was carried out to compare the predicted performance with that obtained in practice by measurement of real-time data using an in-cavity pressure sensor. For the selected materials, the optimum formulation is 4 wt% organoclay (DK4), 4 wt% compatibiliser (Polybond 3200, PPgMA) and 1.5 wt% co-intercalant (erucamide), as the maximum interlayer spacing of clay can be achieved in the selected experimental range. Furthermore, DoE investigations determined that a screw speed of 159 rpm and a feed rate of 5.4 kg/h are the optimum compounding conditions for the twin screw extruder used to obtain the highest tensile modulus and yield strength from the PPCN compounds. The optimised formulation of PPCNs and compounding conditions were adopted to manufacture PPCN materials for the study of thin-wall injection moulding. In the selected processing window, tensile modulus and yield strength increase significantly with decreasing injection speed, due to shear-induced orientation effects, exemplified by a significantly increased frozen layer thickness observed by optical microscopy (OM) and Moldflow® simulation. Furthermore, the TEM images indicate a strong orientation of clay particles in the flow direction, so the PPCN test pieces cut parallel to the flow direction have 36.4% higher tensile modulus and 13.6 % higher yield strength than those cut perpendicular to the flow direction, demonstrating the effects of shear induced orientation on the tensile properties of thin-wall injection moulded PPCN parts. In comparison to injection speed, mould temperature has very limited effects in the selected range investigated (25-55 °C), in this study. The changes in moulding conditions show no distinctive effects on PP crystallinity and intercalation behaviour of clay. Impact toughness of thin wall injection moulded PPCN parts is not significantly affected by either the changes in moulding conditions or clay concentration (1-5 %). The SEM images show no clear difference between the fracture surfaces of PPCN samples with different clay concentrations. TEM and XRD results suggest that higher intercalation but lower exfoliation is achieved in PPCN parts with higher clay content. The composites in the thin sections (at the end of flow) have 34 % higher tensile modulus and 11 % higher yield strength than in the thicker sections, although the thin sections show reduced d001 values. This is attributed to the significantly enhanced shear-induced particle/molecular orientation and more highly oriented frozen layer, according to TEM, OM and process simulation results. In terms of the reduced d001 values in the thin sections, it is proposed that the extreme shear conditions in the thin sections stretch the PP chains in the clay galleries to a much higher level, compaction of clay stacks occurs as less interspacing is needed to accommodate the stretched chains, but rapid cooling allows no time for the chains to relax and expand the galleries back. Overall, data obtained from both actual moulding and simulation indicate that injection speed is of utmost importance to the thin-wall injection moulding process, development of microstructure, and thus the resulting properties of the moulded PPCN parts, in the selected experimental ranges of this research.

Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2010. / ENGLISH ABSTRACT: This project investigates the use of Rapid Prototyping (RP), with specific focus on Three Dimensional Printing (3DP), in the manufacture of complex shaped advanced composite parts, using variants of the Resin Transfer Moulding (RTM) method of composite manufacture. This study developed design guidelines, cost models and a process chain by studying data obtained by making example parts, from literature and consultation with industry. Advanced composite materials offer some of the best low weight and high specific strength properties for the solution of design problems. A major disadvantage of these processes, however, is the low production rates possible and the need of costly moulds. The 3DP technologies combined with the RTM composite process was found to enable a lowering of costs and increase in productivity if smaller batch sizes are considered. The most meaningful area of application for RP techniques seems to be for smaller and more complex components. The geometrical freedom allowed by RP technologies allowed the manufacture of parts which are challenging to manufacture by conventional technology such as CNC machining. Example part case studies were completed for a simple part utilising the one sided mould Resin Infusion RTM variant as well as for a complex part utilising the closed mould Vacuum Assisted Resin Transfer Moulding (VARTM) process variant. During these two case studies it was clear that proper part infusion with resin is critical for the manufacture of good quality composite parts free of voids and dry spots. It is possible to improve the resin infusion by correct placement of resin inlet and outlet ports as well as resin channels incorporated in the mould. Correct placement of these features for the case studies was obtained through simulations done with RTM-Worx software. Results also indicated that another useful application of RP technology to RTM is the manufacture of disposable cores for parts with thick cross sections. Resin channels were included on the surface of these cores to improve the mould filling with resin and consequently part quality. An early cost estimation model, based on the work of Veldsman (1995), was developed for the combined RP and RTM manufacturing process. This model may help designers to eliminate expensive design features and enables a quick cost comparison with competing processes. Drawbacks of applying RP techniques to RTM include the limited lifetime of moulds produced with 3DP and the size and accuracy limitations of the RP t echnology. / AFRIKAANSE OPSOMMING: Hierdie projek handel oor die toepassing van die drie-dimensionele druk metode van Snel-Prototipering (Rapid Prototyping) op die vervaardiging van komplekse gevorderde saamgestelde materiaal komponente met die Hars-Inspuit Giet (Resin Transfer Moulding) metode. Die projek behels die opstel van ontwerpsriglyne, koste-modelle en ’n proses-ketting deur data te bestudeer wat bekom is deur middel van die vervaardiging van eksperimentele parte, literatuurstudie asook raadpleging met individue in die industrie. Gevorderde saamgestelde materiale verskaf van die beste sterk, dog ligte oplossings vir sekere ontwerpsprobleme. ’n Ernstige nadeel van hierdie materiale is egter die stadige produksietempo moontlik en die vereiste van duur gietstukke. Die Snel- Prototipering metodes, gekombineerd met ’n saamgestelde materiaal vervaardigingsproses, maak laer kostes met beter produktiwiteit moontlik indien ontwerpers die part grootte- en akkuraatheidsbeperkings in ag neem. Die mees betekenisvolle area van toepassing blyk kleiner en meer komplekse komponente te wees. Die vryheid in geometrie wat moontlik gemaak word deur die Snel- Prototipering tegnologie laat die vervaardiging toe van parte wat uitdagend is om te vervaardig met konvensionele tegnologie soos CNC masjinering. ’n Gevallestudie is voltooi vir ’n eenvoudige part vervaardig met die enkelkant gietstuk vakuum-infusie weergawe van die Hars-Inspuit Giet metode asook vir ’n komplekse part wat vervaardig is met die geslote gietstuk Vakuum Hars-Inspuit Giet weergawe van die basiese metode. Dit het tydens die twee gevallestudies duidelik geword dat deeglike hars infusie van kritieke belang is vir die vervaardiging van goeie kwaliteit parte sonder enige droë kolle of lugruimtes. Dit is moontlik om die hars infusie te verbeter deur hars inlate en uitlate asook hars kanale in die korrekte posisies te plaas. Die korrekte posisies vir hierdie komponente is verkry deur middel van ’n reeks simulasies met die RTM-Worx sagteware. Resultate dui ook daarop dat Snel-Prototipering tegnologie handig te pas kom by die vervaardiging van verbruikbare kerne vir saamgestelde materiaal parte met groter diktes. Hars kanale kan maklik op die kerne se oppervlak geskep word om die hars verspreiding en gevolglik part kwaliteit te verbeter. ’n Vroeë kostevoorspellings model, gebaseer op werk voltooi deur Veldsman (1995), is saamgestel vir die gekombineerde Snel-Prototipering en Hars-Inspuit Giet proses. Hierdie model kan gebruik word om duur ontwerpsbesonderhede op parte te elimineer en om ’n vinnige koste vergelyking met ander vervaardigingsprosesse te toon. Nadele van die toepassing van Snel-Prototipering tegnieke op Hars-Inspuit Giet sluit die beperkte gietstuk-leeftyd en beperkte akkuraatheid in.

This thesis describes the optimization process for the pitchfork developed by the company Sverigegrepen. The work was done at the department of Applied Mechanics at Uppsala University. The project were handed by Ångström Materials Academy together with Sverigegrepen The work included a major prestudy of plastic construction, plastic materials, plastic injection and strength of materials. By applying the laws of beam theory, a mathematical expression could be provided, explaining the behaviour of the pitchforks teeth. By studying the pitchfork with tools such as 3D- CAD and FEA-simulations, an area where high concentrations of stress were found, an area known to have frequent issues with strength. From this data several concepts were created with an increased strength and a better distribution of stress. The plastic material was evaluated and tested to find the most valuable material characteristics. The provided information was used to isolate different functions in plastic materials, which is crucial for the pitchforks further functionality.

Thesis (MScAgric)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: Green mould is a major citrus postharvest disease caused by a wound pathogen called Penicillium digitatum. Imazalil (IMZ) is the most important postharvest fungicide that is currently registered against green mould and blue mould, given its good protective and curative control and sporulation inhibition. Imazalil can be applied in drench, dip, spray and wax coating applications. Wax coatings improve the quality of the fruit during shelf life by limiting moisture loss and providing a shiny appearance. The primary objective of this study was to investigate the application of imazalil in wax coatings in citrus packhouses to control green mould and preserve fruit quality. The first aim of this study was to evaluate the protective and curative control and sporulation inhibition of IMZ sensitive and resistant isolates of P. digitatum following single IMZ application in wax coating and IMZ application in aqueous dip as well as wax coating. For single application, Valencia orange fruit was curatively or protectively treated with a carnauba-based coating into which IMZ at 3000 μg.mL-1 was mixed. For curative treatments, fruit was treated after 24 hour's incubation. Coating was applied at 0.6, 1.2 and 1.8 L.ton-1 of fruit on a commercial coating applicator. Untreated control and fruit treated with coating only showed up to 80% infection for both sensitive and resistant isolates. Imazalil in coating proved to have better protective than curative action against the sensitive isolate, while control of the resistant isolate was poor. Imazalil residue levels increased with increasing coating load (0.85 to 1.75 μg.g-1). For double application, clementine, satsuma, navel and Valencia orange fruit were used. Curative and protective control following dip only treatment (IMZ sulphate at 500 μg.mL-1 for 45 s and 90 s) was compared with coating only treatment (IMZ at 3000 μg.mL-1 at 1.8 L.ton-1), and double application comprising dip (45 s in IMZ sulphate at 500 μg.mL-1) followed by 2000 μg.mL-1 IMZ in coating at 0.6, 1.2 and 1.8 L.ton-1. Double application resulted in improved residue loading (0.85 to 2.06 μg.g-1) compared to dip only treatments (≈ 0.49 μg.g-1). Coating only resulted in the highest residue levels (1.82 to 7.09 μg.g-1), often exceeding the maximum residue limit of 5 μg.g-1. In all treatments, poor curative and protective control of the resistant isolate (<46% and <55%, respectively) and generally no sporulation inhibition was observed. For the sensitive isolate, dip only treatments resulted in better curative control (≈ 77%) than protective control (≈ 38%). Double application showed increased protective control with increasing wax load (≈ 69%) as well as good curative control (≈ 83%). Wax coating only treatment resulted in poor curative control (≈ 26%), but good protective control (≈ 80%). Sporulation inhibition of the sensitive isolate was generally improved in treatments that included IMZ application in the wax coating. This study successfully showed the additive benefits of double application of IMZ in the wax coating following an aqueous dip application. However, despite improved control of the sensitive isolate, the resistant isolate could not be controlled. The second objective of the study was to evaluate green mould control and quality preservation following IMZ application using different coating and brush types. The inoculation and treatment procedure was similar to the single application of wax coating described above but only the sensitive isolate of P. digitatum was used. Carnauba- or polyethylene-based wax coatings, including IMZ at 3000 μg.mL-1, was applied at a dosage of 0.6, 1.2 and 1.8 L.ton-1 using commercial horsehair or synthetic brushes. Fruit was either incubated for 4 days prior to wound infection ratings or stored at -0.5oC for 26 days and 7 days shelf life. Imazalil residues on fruit increased with increasing coating loads on navel oranges (1.31 to 3.32 μg.g-1) and Valencia oranges (3.22 to 6.00 μg.g-1). Better protective (≈ 58%) than curative control (≈ 14%) was observed, with horsehair brushes resulting in lower sporulation levels (≈ 59%) than synthetic brushes (≈ 64%). Fruit weight loss and firmness loss ratios relative to uncoated control fruit were significantly higher in fruit treated with polyethylene coating compared with carnauba coating treated fruit. However, polyethylene coating resulted in shinier fruit before and after storage, whereas carnauba coating resulted in lower shine ratios. Gaseous (CO2) exchange ratios remained similar for both coatings, but higher polyethylene coating loads (1.8 L.ton-1) resulted in off-tastes similar to the uncoated control fruit and higher than the ratings for carnauba. Scanning electron micrographs revealed an amorphous crystallised natural wax layer with uncovered stomatal pores on the surface of uncoated fruit. The thickness of the applied coating layer increased with increasing coating load. Coating layers following application with synthetic brushes at 1.2 L.ton-1 appeared to be thicker than when applied using horsehair brushes. This study indicated the effects of brush type on the distribution and polishing of the wax coating on the surface of the fruit and also the importance of cautious application of coating as under or over application may lead to poor results in terms of bio-efficacy, residue loading and fruit quality. / AFRIKAANSE OPSOMMING: Groenskimmel is 'n belangrike sitrus na-oessiekte, veroorsaak deur 'n wondpatogeen, genaamd Penicillium digitatum. Imazalil (IMZ) is die belangrikste na-oesfungisied wat tans teen groenskimmel geregistreer is, gegewe sy goeie beskermende en genesende beheer en sporulasie-inhibisie. Imazalil kan in bad-, doop-, spuit- en wakslaagbehandelings toegedien word. Wakslae behou die kwaliteit van die vrugte gedurende raklewe deur vogverlies te beperk en 'n glansvoorkoms te verskaf. Die primêre doel van hierdie studie was om die toediening van imazalil in wakslaagbehandelings in sitruspakhuise vir groenskimmel en vrugkwaliteit beheer te ondersoek. Die eerste doelwit van hierdie studie was om die beskermende en genesende beheer en sporulasie-inhibisie van IMZ sensitiewe en weerstandbiedende isolate van P. digitatum, gevolg deur enkel IMZ toediening in 'n wakslaagbehandeling, en IMZ toediening in 'n doop-, asook wakslaagbehandeling, te evalueer. Vir enkelltoediening is Valencia lemoenvrugte genesend of beskermend met 'n carnauba-gebaseerde wakslaag behandel, waarin IMZ teen 3000 μg.mL-1 gemeng is. Vir genesende behandelings is vrugte ná 24 uur inkubasie behandel. Wakslaagbehandeling is teen 0.6, 1.2 en 1.8 L.ton-1 vrugte op 'n semi-kommersiële paklyn toegedien. Onbehandelde kontrole en vrugte met waks behandel, het slegs tot 80% infeksie vir beide sensitiewe en weerstandbiedende isolate getoon. Imazalil in waks het beter beskermende as genesende aksie teen die sensitiewe isolaat getoon, terwyl beheer van die weerstandbiedende isolaat swak was. Imazalil residuvlakke het met toename in wakslading toegeneem (0.85 tot 1.75 μg.g-1). Vir dubbeltoediening is clementine, satsuma, navel en Valencia lemoenvrugte gebruik. Genesende en beskermende beheer van IMZ na enkel doopbehandeling (IMZ sulfaat teen 500 μg.mL-1 vir 45 s en 90 s), is met enkel waksbehandeling (IMZ teen 3000 μg.mL-1 teen 1.8 L.ton-1) vergelyk, asook dubbeltoediening bestaande uit doop (45 s in IMZ sulfaat teen 500 μg.mL-1), gevolg deur 2000 μg.mL-1 IMZ in waksbehandeling teen 0.6, 1.2 en 1.8 L.ton-1. Dubbeltoediening het verbeterde residulading (0.85 tot 2.06 μg.g-1) tot gevolg gehad, in vergelyking met enkel doopbehandelings (≈ 0.49 μg.g-1). Enkel waksbehandeling het die hoogste residuvlakke (1.82 tot 7.09 μg.g-1) tot gevolg gehad, wat dikwels die maksimum residu-limiet van 5 μg.g-1 oorskry het. In alle behandelings is swak genesende en beskermende beheer van die weerstandbiedende isolaat (<46% en <55%, onderskeidelik), en oor die algemeen, geen sporulasie-inhibisie, waargeneem. Vir die sensitiewe isolaat, het die enkel doopbehandelings beter genesende beheer (≈ 77%) in vergelyking met die beskermende beheer (≈ 38%) tot gevolg gehad. Dubbeltoediening het verhoogde beskermende beheer met toenemende wakslading (≈ 69%) getoon, asook goeie genesende beheer (≈ 83%). Enkel wakslaagbehandeling het swak genesende beheer (≈ 26%) tot gevolg gehad, maar goeie beskermende beheer (≈ 80%). Sporulasie-inhibisie van die sensitiewe isolaat was oor die algemeen beter in behandelings wat IMZ toediening in die wakslaag ingesluit het. Hierdie studie het suksesvol die toegevoegde voordele van dubbeltoediening van IMZ in doopbehandeling en wakslaag getoon. Ten spyte van die verbeterde beheer van die sensitiewe isolaat, kon die weerstandbiedende isolaat egter nie beheer word nie. Die tweede doelwit was om groenskimmelbeheer en behoud van kwaliteit te evalueer, volgende op IMZ toediening deur gebruik van verskillende waks- en borseltipes. Inokulasie- en behandelingsprosedure was soortgelyk aan die enkeltoediening van wakslaagbehandeling soos bo beskryf, maar slegs die sensitiewe isolaat van P. digitatum is gebruik. Carnauba- of poli-etileen-gebaseerde wakslae, insluitende IMZ teen 3000 μg.mL-1, is teen 'n dosis van 0.6, 1.2 en 1.8 L.ton-1 toegedien, deur die gebruik van kommersiële perdehaar of sintetiese borsels. Vrugte is óf vir 4 dae vóór wond-infeksie evaluering geïnkubeer, óf teen -0.5oC vir 26 dae en 7 dae raklewe gestoor. Imazalil residuvlakke op vrugte het met toenemende waksladings op navellemoene (1.31 tot 3.32 μg.g-1) en Valencia lemoene (3.22 tot 6.00 μg.g-1) toegeneem. Beter beskermende (≈ 58%) as genesende beheer (≈ 14%) is waargeneem, met perdehaar borsels wat laer sporulasievlakke (≈ 59%) tot gevolg gehad het, in vergelyking met sintetiese borsels (≈ 64%). Vruggewig- en fermheidsverlies verhoudings, relatief tot onbedekte kontrole vrugte, was betekenisvol hoër in vrugte wat met 'n poli-etileenwaks behandel is, in vergelyking met carnauba-waks behandelde vrugte. Poli-etileen waksbehandeling het egter blinker vrugte vóór en ná opberging tot gevolg gehad, terwyl canauba waksbehandeling laer blink verhoudings tot gevolg gehad het. Gas (CO2) uitruilverhoudings het dieselfde vir beide waksbehandelings gebly, maar hoër poli-etileen waksladings (1.8 L.ton-1) het tot afsmake soortgelyk aan die onbedekte kontrole vrugte gelei, en hoër as die evaluerings vir carnauba. Skandeer-elektronmikrograwe het 'n amorfe gekristalliseerde natuurlike wakslaag met onbedekte stomata op die oppervlak van onbedekte vrugte getoon. Die dikte van die toegediende waks het met toename in wakslading toegeneem. Wakslae na toediening met sintetiese borsels teen 1.2 L.ton-1 het dikker vertoon in vergelyking met perdehaar borsels. Hierdie studie het die effekte van borseltipe op die verspreiding en polering van die wakslaag op die oppervlak van vrugte getoon, en versigtige toediening van wakslae onderskryf, aangesien ónder- of óórtoediening swak resultate, in terme van bio-effektiwiteit, residu-lading en vrugkwaliteit, tot gevolg kan hê. / National Research Foundation, THRIP, Citrus Academy & Citrus Research International for bursary and research funding.

De senaste decennierna har visat på en stor ökning av den textila konsumtionen som följd av efterfrågan, samtidigt som den textila återvinningen idag är nästintill obefintlig. Detta leder till att mycket av det textila materialet deponeras istället för att återvinnas, vilket innebär ett stort slöseri av redan befintlig råvara som skulle kunna användas till att skapa nytt textilt material. Genom att undersöka olika återvinningsmetoder och -processer skulle denna råvara kunna användas på nytt. Examensarbetet är en del av forskningsprojektet ”Från spill till guld” som leds av forskningsinstitutet Swerea IVF. Forskningsprojektets utgångspunkt är att minimera produktionsspill och att höja dess värde inom bland annat textilindustrin. Examensarbetet syftar till att undersöka termomekanisk återvinning av plagg gjorda av polyamid 6.6 (PA6.6) och elastan, smältspinna filament samt formspruta provstavar från denna nya polymerblandning utan att separera fibrerna. Andra syftet är att även hitta en lösning för produkterna som undersöks i detta examensarbete kan återvinnas i sin helhet, så att ingen demontering av produkterna ska behövas. Fyra olika plagg undersöktes i examensarbetet bestående av materialblandningen PA6.6 och elastan. Analyser av de fyra olika plaggen genomfördes för att fastställa materialen. Hela plagg tillverkade i de olika materialen klipptes eller maldes ned och smältes sedan om genom kompoundering, därefter tillverkades granulat. Materialen testades i spinnbarhet genom smältspinningsförsök, sedan smältspanns eller formsprutades materialen. Resultaten från smältspinningsförsöken analyserades i ljusmikroskop för att avgöra om elastanen är termoplastiskt eller inte då detta är en avgörande faktor vid smältspinning. Olika tester gjordes på materialen för att undersöka deras eventuella kemiska nedbrytning som resultat av kompoundering. Resultatet visade att smältspinning och formsprutning inte är möjligt från denna polymerblandning. Ett antagande kan göras att återvinningen inte fungerade på grund av PA6.6:s höga smälttemperatur, då elastanen antagligen bryts ned vid denna höga temperatur, vilket förstör materialet. Slutsatsen blir då att smältspinning och formsprutning inte är möjligt utifrån denna polymerblandning, men återvinning till plastdetaljer kan produceras vid kompounderingsstadiet och återanvändas i annan industri än textilindustrin. Potential finns för återvinning av plagg till plagg om ändringar görs under processens gång och om elastanen identifieras som termoplastisk eller inte. / The latest decades have shown a large increase in textile consumption as a result of demand, at the same time the textile recycling today is almost non-existent. This means that much of the textiles are used for landfill rather than being recycled, which generates a large waste of raw material that could be used to create new textiles. By exploring various recycling methods and processes this raw material could be used again. This thesis is part of a research project, “From Waste To Gold”, which is led by the research institute Swerea IVF. The research projects foundation is to minimize production waste and to increase its value in areas such as textile industries. This thesis’ foundation is to examine the mechanical recycling of garments made by polyamide 6.6 (PA6.6) and spandex, melt spin filaments and produce injection moulded samples from this new polymer blend, without separating the fibres. The other foundation is to find a solution for the products that are examined in this thesis so they could be recycled as a unit, no disassembly of the products would be necessary Four different garments was examined in this thesis, the materials were a combination of PA6.6 and spandex. Different analyses were made on the four different garments. Whole garments from the different materials were cut or milled and then re melted through compounding, after compounding granulates was made. The materials spin ability was tested through melt spinning trials, then the materials were either melt spun or injection moulded. The results from the spinning trials was analysed in a light microscope to examine if the spandex were thermoplastic or not, as this is a crucial factor when melt spinning. Various tests were conducted to analyse their chemical degradation after the compounding. The results from the melt spinning and injection moulding showed that it was not possible to recycle this polymer combination this way. An assumption can be made that the recycling methods did not work because of the high melt temperature of PA6.6, the spandex assumes to decompose at this high temperature and therefore destroys the material. The conclusion is that melt spinning and injection moulding is not possible to conduct with this polymer combination, but recycling to plastic details could be done at the compound stage and then be used in some other industry, not in the textile industry. There are potential for garment-to-garment recycling if changes are made during the recycling processes and if the spandex could be identified as a thermoplastic or a non-thermoplastic.

Micrometer injection moulding is a type of moulding in which moulds have geometrical design features on a micrometer scale that must be transferred to the geometry of the produced part. The difficulties encountered due to very high shear and rapid heat transfer of these systems has motivated this investigation into the fundamental mathematics behind polymer heat transfer and associated processes. The aim is to derive models for polymer dynamics, especially heat dynamics, that are considerably less approximate than the ones used at present, and to translate this into simulation and optimisation algorithms and strategies, Thereby allowing for greater control of the various polymer processing methods at micrometer scales.

Les contributions de cette thèse de doctorat sont focalisées sur les développements de formulations à base de polymères bio sourcés et déliantable à l’eau basés sur l’emploi d’acétate butyrate de cellulose (CAB) et de polyéthylène glycol (PEG). Ces nouvelles formulations ont été appliquées sur différentes nuances de poudres métalliques (invar) et céramiques (zircones). Ces matériaux possèdent une bonne stabilité dimensionnelle sous une large gamme de température imposée et possèdent de très bas coefficients d’expansion thermique.L’objective est l’étude et la compréhension du comportement des liants à base de CAB et PEG quand ils sont utilisés dans les variantes du procédé MIP (étapes de moulage avec ou sans pression, conditions particulières liées à la micro-injection, …) réalisées avec différentes nuances de poudres et différentes granulométries.Les caractéristiques intrinsèques de chaque CAB, leurs interactions avec le PEG et les poudres, l’influence de la nuance de poudre employée, ainsi que la granulométrie et la morphologie des poudres employées ont été étudiées et analysées en fonction du comportement final de la formulation développé et des taux de charges obtenues.L’homogénéité des mélanges développés, leurs taux de charge critique et maximal, ainsi que leurs comportements mécaniques, thermiques et rhéologiques ont été analysés et investigués par différentes études mécaniques, thermo et physico-chimiques. De nouvelles analyses chimiques et physiques ont été introduites par accroitre les connaissances sur les formulations développées. Les formulations optimales ont été validées pour différentes applications et avec l’emploi de différentes variantes du procédé MIP conduisant à l’élaboration de composants et de micro-composants PIM obtenus sans défauts et possédant d’excellentes propriétés fonctionnelles. L’étape de déliantage ainsi que l’étape de densification ont été optimisées en termes de cinétique et d’atmosphère aboutissant aux propriétés physiques et mécaniques escomptées pour l’ensemble des nuances de poudres considérées dans cette étude.En conclusion, les formulations développés des liants basées sur l’emploie de CAB et PEG sont exploitable au niveau de la recherche et au niveau industriel dans le procédé MIP. Elles apportent des améliorations par rapport aux liants conventionnels grâce à un procédé plus écologique. Cette première contribution représente une avancée significative dans l’émergence d’un procédé MIP plus écologique mais d’autres travaux futurs sont encore possibles. / This PhD Thesis studied the use of binders based on cellulose acetate butyrate (CAB) andpoly(ethylene glycol) (PEG) in different type of materials, including a ceramic, the zirconiumsilicate, and a metallic alloy, the Invar 36. These materials share their low dimensionalstability with temperature with low coefficients of thermal expansion.The scope of this work is the study and comprehension of the behaviour of the mentionedbinder systems when they are employed in different PIM processes and under differentconditions and powder-types. With regard to this matter, different formulations were designedwith several types of PEG and CAB. These formulations were compared with commercialones. The intrinsic characteristics of each CAB were linked with the behaviour of the differentfeedstock also containing PEG and powder particles. The mixtures homogeneity, the optimumand critical solid loading and its flowability were assessed by torque and capillary rheology.Other complementary techniques such as electronic and light microscopy or the measurementof the mixtures densities by pycnometry were carried out to contrast rheology results. Thecompatibility between the feedstocks’ components and their thermal behaviour were analysedby calorimetry and thermogravimetry techniques. These methods were employed by the firsttime to determine the optimal solid loading.The optimal compositions were injected by using low or high pressures or by a micro injectionmoulding process. The debinding and sintering stages were optimised using severalatmospheres. Finally, the physical and mechanical properties of the final consolidated partswere measured.It could be concluded that the studied binder systems based on PEG and CAB presentedsuitable characteristics for PIM, providing improvements with respect to conventional bindersystems and by a more environmental friendly processing. However, that doctoral work wasjust a first approach to the use of these types of binder systems in PIM. Along this workseveral issues were detected and some topics regarding the processing should be furtherinvestigated to obtain the best of these binder systems.

Biobased thermoset resins were synthesized by functionalizing the tall oil fatty acid with hydrogen peroxide and then methacrylic anhydride. The obtained resins were characterized by FTIR to confirm the conversions. The cross-linking ability of the resins were checked by curing experiments and followed by DSC analysis regarding the extent of cross linking. TGA analysis was conducted to identify the thermal degradation patterns of cured resins. The obtained resins (blended with or without 33wt% styrene) were used as matrix and knitted viscose fibers were used as reinforcements to make bio-based composites. Ten layers of knitted viscose fibers were stacked crosswise (0/90⁰С) and hand lay-up impregnation was performed. The fiber ratio of all composites was around 63-66%. The composites were characterized by flexural testing, dynamic mechanical thermal analysis and charpy testing. This work demonstrates that manufacture of composites with both matrix and reinforcement fiber coming from renewable resources is feasible, and the resulted composites have satisfied mechanical performance. / Program: MSc in Resource Recovery - Sustainable Engineering

The feasibility of the injection moulding (IM) was explored for the development of novel drug delivery systems. Controlled release formulations were developed using a substituted cellulose derivative, hydroxypropyl methyl cellulose acetate succinate (HPMCAS) and a graft co-polymer (Soluplus®). BCS class II drugs ibuprofen and the felodipine were selected based on their physicochemical properties. In the present work, a homogenous dispersion of drugs in the polymer matrices was achieved using Hot Melt Extrusion (HME) and extruded pellets obtained were used for the development of the injection moulded systems. Four systems were developed using the IM consisting of ibuprofen-HPMCAS, ibuprofen-Soluplus®, felodipine-PEO-HPMCAS and felodipine-Soluplus®. The ibuprofen acts as a good plasticiser compared to felodipine therefore, felodipine containing IM systems required a plasticiser (PEO) when processed with HPMCAS. The analysis of extruded pellets and injection moulded systems using modulated DSC (MDSC) and Raman spectroscopy confirmed the formation of an amorphous molecular dispersion (i.e solid solution) in the case of all four systems. The phase separation behaviour and the amorphous stability of the systems was studied at various stress conditions. This revealed the “surface crystallisation” behaviour of the ibuprofen-HPMCAS systems. Temperature-composition phase diagram constructed based on the melting point depression and the Flory-Huggins lattice solution theory provided the explanation for the phase separation and crystallisation behaviour of ibuprofen-HPMCAS systems. The advanced characterisation techniques like DMA, 2D XRD and 3D laser microscopy provided the detailed understanding of crystal habits, phase seperation and surface crystallisation. The significant effect of the stress conditions on the rate of shrinkage was observed where, higher shrinkage tendency of a HPMCAS IM system was observed compared to Soluplus® IM systems. The extruded pellets provided the faster drug release compared to the moulded tablets suggests the effect of particle size as well as the densification during IM on the dissolution rate of the dosage form. The nature of the polymer and processing history were the contributing factors for the dissolution of the dosage forms.