The presented research focused on the evaluation of the novel concept of overmolding technique using self-reinforced composite prepregs and recycled polymer blends. In order to evaluate the effectiveness of the proposed manufacturing technique, several series of materials based on polycarbonate/polyethylene terephthalate (PC/PET) and polycarbonate/polyethylene terephthalate glycol (PC/PETG) blends were prepared. The reinforcing component in the form of overmolded prepreg was made from polyester-based self-reinforced composite (srPET). The prepared materials were compared in terms of mechanical properties and heat resistance; the study was supplemented by thermal analysis measurements (DMTA, DSC). Considering the mechanical characteristics, the overmolding technique turns out to be an effective method of improving the properties of composites, and the increase in impact strength turns out to be particularly beneficial. The increase of the impact strength for overmolded PC/PET blend reached 430 % for PC/PETG sample 330% , while for PC-based composite, only 100%. The expected improvement in thermomechanical properties turned out to be difficult to achieve due to the rapid softening of the srPET prepreg at around 70 °C. However, technological tests and analysis of properties clearly indicated that the use of PC-based blends makes it possible to create a permanent connection with reinforcement based on srPET prepregs, which can significantly expand the potential of applications of this type of materials.

The subject of the conducted study was focused on the development of new type of technical blends reinforced with natural fillers. The study was divided into two parts, where in the firsts stage of the research unmodified POM was reinforced with different types of natural fillers: cellulose, wood flour and husk particles. In order to select the type of filler intended for further modification, the mechanical characteristics was assessed. The 20% wood flour (WF) filler system was selected as the reinforcement. The second stage of research involved the use of combination of polyoxymethylene POM and poly(lactic acid) PLA. POM/PLA blend (ratio 50/50 %) were modified with elastomeric compound (EBA) and chain extender as reactive compatibilized (CE). The microscopic analysis revealed that for POM/PLA system the filler-matrix interface is characterized by better wettability, which might suggest higher adhesion. The mechanical performance revealed that for POM/PLA-based composites the properties were very close to the results for POM-WF composites; however, there is still large difference in thermal resistance in favor of POM-based materials. The increase in thermomechanical properties for POM/PLA composites occurs after heat treatment. The increasing crystallinity of the PLA phase allows for an significant increase of the head deflection temperature (HDT), even above 125 °C.