Lightweight component design is effectively achievable through the sandwich structures, many past research studies in the aerospace and racing sectors (since 1920s) has proven it. To extend their application into automotive and other transport industries, the manufacturing cycle times must be reduced. This can be achieved by thermoplastic sandwich materials of continuous fibre-reinforced thermoplastic (CFRTP) cover layers and thermoplastic honeycomb cores. To widespread the application of flat thermoplastic-based sandwich panels into complex parts, a novel forming technology was developed by the Fraunhofer Institute of Microstructure of Materials and Systems (IMWS). For an increase in reproducibility of the sandwich component production and a decrease in manufacturing defects, numerical modelling methods and experimental validation are needed. The finite element (FE) modelling of this thermoforming process is a thermo-mechanical assignment with all three: material, geometry, and boundary non-linearities. In the scope of this work, the material behavior of different sandwich components (cover layers, honeycomb core, interface) under thermo-mechanical loads is characterized in detail, and a complex numerical model is developed to describe the thermoforming process of thermoplastic-based sandwich laminate. The critical forming condition like wrinkling that occurs due to friction in a sandwich or poor intra-ply shear in cross-ply studied, validated, and optimized. A thermoplastic sandwich made of polypropylene (PP) honeycomb core and polypropylene glass fibre (PP/GF) cross-ply as cover layers was used for this study, and numerical modelling was executed in LS-DYNA software.

The practical application of a multi-objective optimization strategy based on evolutionary algorithms was proposed to optimize the plastics thermoforming process. For that purpose, the various steps of the process were considered individually and the optimization strategy was applied to the determination of the final part thickness distribution with the aim of demonstrating the validity of the methodology proposed. The preliminary results obtained considering three different theoretical initial sheet shapes indicates clearly that the methodology proposed is valid, as it provides solutions with physical meaning and with a great potential to be applied in real practice.

The aim of the study is to investigate the effects of artificial aging by thermocycling and mechanical loading on force/torque delivery by thermoplastic orthodontic aligners. Ten thermoformed aligners made of Zendura™ thermoplastic polyurethane sheets were aged over two weeks in deionized water by thermocycling alone (n=5) and by both thermocycling and mechanical loading (n=5). The force/torque generated on upper second premolar (Tooth 25) of a plastic model was measured before aging (as control), and after 2, 4, 6, 10, and 14 days of aging, using a biomechanical set-up. Before aging, the extrusion-intrusion forces were in the range of 2.4 to 3.0 N, the oro-vestibular forces were 1.8 to 2.0 N, and the torques on mesio-distal rotation were 13.6 to 40.0 Nmm. Pure thermocycling had no significant effect on the force decay of the aligners. However, there was a significant decrease in force/torque after 2 days of aging for both thermocycling and mechanical loading aging group, which is no longer significant over 14 days of aging. In conclusion, artificial aging of aligners in deionized water with thermocycling and mechanical loading results in a significant decrease in force/torque generation. However, the mechanical loading of aligners has a greater impact than thermocycling alone.

The increased consumption of food requiring thermoformed packaging means that the packaging industry demands customized solutions in terms of shapes and sizes to make the packaging unique. In particular, the food industry increasingly requires more transparent packaging, with greater clarity and a better presentation of the product features they contain. However, in turn, the differentiation of products is sought through the geometry and final finish of the product, as well as the arrangement of food inside the packaging. In addition, these types of packaging usually include ribs in the walls to improve physical properties, however they also affect the final aesthetics of the product. In accordance with this, this research study analyses by studying the mechanical properties of different relief geometries that can affect not only the aesthetics but also their strength. For this purpose, tensile and compression tests have been carried out. The results provide comparative data on the reliefs studied and show that there are different shapes, sizes and layout.

This experimental study probes the dynamic behaviour of a 3mm ABS sheet during positive mould vacuum-assisted thermoforming. In this process, the sheet undergoes large and fast deformations, caused by the applied vacuum and mechanical stretching by the mould. The objective is to elucidate the complexities of these large, rapid and non-isothermal deformations. The non-isothermal conditions are caused by the radiative heating of the sheet, convective heat loss to the surrounding air and conductive heat transfer from the sheet to the mould. Utilizing stereo Digital Image Correlation (DIC) in tandem with thermal imaging, the present study accurately maps the occurring displacement, strain and strain rate field in relation to real-time temperature variation of the material. The study progresses to observe the ABS material from the moment it contacts the mould until it conforms to a positive 250mm diameter semi-sphere cast aluminium mould. The DIC methods are validated by comparing thickness values derived from DIC’s principal strain directions to ultrasonic thickness gauge readings. This knowledge not only broadens the understanding of the thermo-mechanical behaviour of the material but also aids in optimizing process parameters for improved thickness uniformity in thermoformed products.

The application of optimization techniques to improve the performance of polymer processing technologies is of great practical consequence, since it may result in significant savings of materials and energy resources, assist recycling schemes and generate products with better properties. The present review aims at identifying and discussing the most important characteristics of polymer processing optimization problems in terms of the nature of the objective function, optimization algorithm, and process modelling approach that is used to evaluate the solutions and the parameters to optimize. Taking into account the research efforts developed so far, it is shown that several optimization methodologies can be applied to polymer processing with good results, without demanding important computational requirements. Also, within the field of artificial intelligence, several approaches can be reach significant success. The first part of this review demonstrated the advantages of the optimization approach in polymer processing, discussed some concepts on multi-objective optimization and reported the application of optimization methodologies in single and twin screw extruders, extrusion dies and calibrators. This second part focus on injection molding, blow molding and thermoforming technologies.

Given the global economic and societal importance of the polymer industry, the continuous search for improvements in the various processing techniques is of practical primordial importance. This review evaluates the application of optimization methodologies to the main polymer processing operations. The most important characteristics related with the usage of optimization techniques, such as the nature of the objective function, the type of optimization algorithm, the modelling approach used to evaluate the solutions, and the parameters to optimize, are discussed. The aim is to identify the most important features of an optimization system for polymer processing problems, and define the best procedure for each particular practical situation. For this purpose, a state-of-the-art of the optimization methodologies usually employed is first presented, followed by an extensive review of the literature dealing with the major processing techniques, the discussion being completed by considering both the characteristics identified and the available optimization methodologies. This first part of the review focus on extrusion, namely extruders, extrusion dies and calibrators. It is concluded that there is a set of methodologies that can be confidently applied in polymer processing, with a very good performance and without the need of demanding computation requirements.

Process induced defects during thermoforming are widespread problems in laminate manufacturing. The aim of this study is to describe the effects of holding time and pressure on several properties of the manufactured laminate. A design of experiments is performed, followed by an analysis of variance to examine significant effects. Subsequently, a regression model is created to predict the laminate’s properties, which is also validated. The highest values of tensile strength and elongation at break are found for low settings of holding time and pressure. The fibre volume fraction is not affected by the process parameters. As holding time and pressure increase, significant fibre misalignment takes place, leading to a decrease of the mechanical properties. The regression model corresponds well with the validation and should be extended with further variables in subsequent studies.