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Polymers
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Polymer Manufacturing Processes
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Polymer Manufacturing Processes

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: 31 July 2025 | Viewed by 1782

Special Issue Editors

Dr. Claudia Pagano

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council of Italy, Milano, Italy
Interests: micro manufacturing; polymers processing; compounding; micro assembly; mechanics of materials; nanoindentation; atomic force microscopy
Dr. Rossella Surace

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council (STIIMA-CNR), Bari, Italy
Interests: injection molding; micro manufacturing; polymer properties and processing; composites; polymeric foams; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Due to technology advancements, consumer demands, and progressively increasing attention to sustainability, polymer manufacturing processes have greatly developed over the last years, and further progress is highly expected. New methodologies have been developed, such as additive manufacturing, which has revolutionized the manufacturing industries, allowing for the production of complex, difficult, and often impossible-to-manufacture parts with traditional methods. The development of new materials and the incentives for recycling have led to the use of innovative plastics and composites and have boosted the related manufacturing techniques. Simulation and predictive maintenance software, robotic automation, integration of the Internet of Things, machine learning algorithms, and life cycle assessment have contributed to improving the efficiency of production technologies. This Special Issue is dedicated to the advances in thermoplastic, thermosetting, and composite polymer manufacturing processes, also including pre- and post-processes and strategies for sustainability. Original research articles and reviews are welcome. Invited and submitted articles should investigate the development of new methodologies or materials, improvement of the state-of-the-art strategies, and combinations of processes. Authors are encouraged to present research addressing different aspects of the product life cycle and industrial applications.

Dr. Claudia Pagano
Dr. Rossella Surace
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • polymer processing
  • sustainability
  • computer-aided manufacturing
  • materials
  • energy efficiency
  • recycling

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Published Papers (5 papers)

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Research

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26 pages, 22416 KiB  
Article
Theoretical and Experimental Study on the Surface Microstructures of Polyimide in Ultra-Precision Fly-Cutting
by Jie Liu, Sheng Wang and Qingliang Zhao
Polymers 2025, 17(8), 1099; https://doi.org/10.3390/polym17081099 - 18 Apr 2025
Viewed by 156
Abstract
Polyimide (PI) with surface microstructures has broad application prospects in aerospace, integrated circuits, and optical engineering due to its excellent mechanical properties, high thermal stability, and chemical resistance. Ultra-precision fly-cutting (UPFC) is a promising advanced technique for machining PI microstructures. However, few studies [...] Read more.
Polyimide (PI) with surface microstructures has broad application prospects in aerospace, integrated circuits, and optical engineering due to its excellent mechanical properties, high thermal stability, and chemical resistance. Ultra-precision fly-cutting (UPFC) is a promising advanced technique for machining PI microstructures. However, few studies on the UPFC of PI materials are reported. In this study, the machining principle of UPFC is analyzed, and a comparative study of different processing strategies is conducted. The experimental results demonstrate that the climb cutting strategy is more suitable for PI microstructure machining, which can significantly reduce burr formation and achieve lower surface roughness. The theoretical models describing tool motion and predicting maximum chip thickness in UPFC are established, and the predicted chip thickness is consistent with the experimental results. Moreover, the influence of process parameters on the surface morphology and dimensional accuracy of microstructures is assessed through a series of experiments. The results indicate that cutting depth and step-over are the dominant factors influencing dimensional accuracy and surface roughness. Furthermore, the cutting force during UPFC is extremely small, only in the range of millinewtons (mN). In addition, the cutting force in the feed direction exhibits a high sensitivity to variations in process parameters compared to other directional components. This study provides theoretical guidance for the establishment of a theoretical model and the selection of UPFC process parameters for fabricating PI microstructures. Full article
(This article belongs to the Special Issue Polymer Manufacturing Processes)
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16 pages, 1674 KiB  
Article
Surface Chemistry and Molecular Dynamics of Epoxy Resin: Insights from Analysis During Curing and Post-Curing Processes
by Bogdan-Marian Tofanica, Elena Ungureanu and Firas Awaja
Polymers 2025, 17(8), 1094; https://doi.org/10.3390/polym17081094 - 18 Apr 2025
Viewed by 126
Abstract
The surface chemistry of epoxy resin and its composites is critical for their long-term performance across various applications. In this study, we investigate the main reactions occurring on the surface of DEGBA/DEGBF epoxy resin following curing, post-curing, and thermal post-curing processes using Time-of-Flight [...] Read more.
The surface chemistry of epoxy resin and its composites is critical for their long-term performance across various applications. In this study, we investigate the main reactions occurring on the surface of DEGBA/DEGBF epoxy resin following curing, post-curing, and thermal post-curing processes using Time-of-Flight Secondary Ion Mass Spectrometry (ToF-SIMS). ToF-SIMS analysis elucidated molecular details, including curing and cross-linking progression, cross-link characteristics, cured resin structure, residual unreacted hardener, cross-linking density, and reaction pathways. Principal Components Regression analysis (PCR) was applied to distinguish between cured and post-cured samples, focusing on specific ions indicative of the curing process. The completion of curing was associated with ions such as C14H7O+, CHO+, CH3O+, and C21H24O4+, while unreacted hardener was indicated by C21H24O4+ ions. Cross-linking density and the intensities of aliphatic hydrocarbons were crucial in differentiating curing stages. Calibration ensured that all ion intensities totaled to one, and specific ions were tracked to monitor the states from uncured to post-cured. Negative spectra provided insights into the consumption of hardener molecules during curing and post-curing. The results demonstrated that post-curing enhances the properties of epoxy resin by promoting further cross-linking, reducing residual unreacted groups, and forming a more extensive covalent network. This results in improved mechanical and thermal stability. The molecular changes observed through ToF-SIMS data effectively distinguish between curing and post-curing reactions, contributing to a better understanding and optimization of epoxy resin properties for various applications. Full article
(This article belongs to the Special Issue Polymer Manufacturing Processes)
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18 pages, 5223 KiB  
Article
Optimization of Resin Composition for Zirconia Ceramic Digital Light Processing Additive Manufacturing
by Ning Kuang, Minghui Xiao, Hao Qi, Wenjie Zhao and Junfei Wu
Polymers 2025, 17(6), 797; https://doi.org/10.3390/polym17060797 - 18 Mar 2025
Viewed by 373
Abstract
In ceramic digital light processing (DLP) additive manufacturing, the photosensitive resin, which acts as a carrier for ceramic particles, must exhibit suitable curing performance, curing strength, and viscosity. This ensures both the bonding strength of the fabricated ceramic parts and the dimensional accuracy [...] Read more.
In ceramic digital light processing (DLP) additive manufacturing, the photosensitive resin, which acts as a carrier for ceramic particles, must exhibit suitable curing performance, curing strength, and viscosity. This ensures both the bonding strength of the fabricated ceramic parts and the dimensional accuracy of the ceramic green body. In this study, various photosensitive resin monomers were investigated in depth to formulate resins containing monofunctional, bifunctional, and multifunctional groups. Their rheological and curing properties were analyzed theoretically and experimentally. Different resin slurry systems were prepared and printed using DLP technology, and their mechanical properties were tested and compared. The effect of photoinitiator content on the curing behavior of the resin was examined, and the optimal photoinitiator concentration was identified. Based on the optimized resin, a zirconia ceramic slurry with 56 vol% solid content was prepared. After DLP printing, debinding, and sintering, dense zirconia ceramic samples with a relatively uniform grain structure were obtained, exhibiting a bending strength of 766.85 MPa. These results significantly expand the potential applications for zirconia ceramic components with complex geometries. Full article
(This article belongs to the Special Issue Polymer Manufacturing Processes)
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18 pages, 4742 KiB  
Article
Research on Modeling for the Flow–Compaction Process of Thermosetting Epoxy Resin-Based Composites
by Ye Jing, Zhenyi Yuan, Kai He, Lingfei Kong, Guigeng Yang and Kaite Guo
Polymers 2025, 17(6), 722; https://doi.org/10.3390/polym17060722 - 10 Mar 2025
Viewed by 413
Abstract
Addressing the issue of porosity evolution during the curing process of thermosetting epoxy resin-based composites, a simulation model has been developed to describe the flow–compaction behavior of the composites aiming to predict changes in porosity throughout the curing process. Initially, a multi-physics coupling [...] Read more.
Addressing the issue of porosity evolution during the curing process of thermosetting epoxy resin-based composites, a simulation model has been developed to describe the flow–compaction behavior of the composites aiming to predict changes in porosity throughout the curing process. Initially, a multi-physics coupling model encompassing sub-models for thermo-chemical, fiber bed compression, void compression, and percolation flow was established. This model accurately describes the changes in porosity within the composites during the flow–compaction process. The UMAT subroutine of the ABAQUS finite element analysis software was utilized to integrate these sub-models into the software. The validity of the simulation model was verified through corresponding experimental porosity measurements. The research further indicates that the porosity at the fillet of L-shaped composite components is higher than that in flat areas due to insufficient shear slip capacity. The results show that the porosity of the rounded corners of the L-shaped composite members is higher than that of the flat plate region due to the lack of shear slip capacity, and the fiber bed stiffness and inter-ply friction coefficient play an important role in the change in porosity. Full article
(This article belongs to the Special Issue Polymer Manufacturing Processes)
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Review

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19 pages, 6080 KiB  
Review
Current Status and Future Trends for Modification Technology of Flame Retardant Nylon 66
by Bingtao Feng, Senlong Yu, Hengxue Xiang, Lili Li and Meifang Zhu
Polymers 2025, 17(8), 1074; https://doi.org/10.3390/polym17081074 - 16 Apr 2025
Viewed by 179
Abstract
Nylon 66 (PA66) has been widely used in automotive, electronics, textiles and other fields due to its excellent mechanical properties, chemical corrosion resistance and thermal stability. However, the fire hazard caused by its flammability severely limits its further application in high–end and high–risk [...] Read more.
Nylon 66 (PA66) has been widely used in automotive, electronics, textiles and other fields due to its excellent mechanical properties, chemical corrosion resistance and thermal stability. However, the fire hazard caused by its flammability severely limits its further application in high–end and high–risk fields. Therefore, improving the flame retardancy of PA66 to enhance its safety has become the focus of current research. This review aims to better understand the research status and development trends of flame retardant PA66. Firstly, the combustion process and flame retardant mechanism of PA66 were described. Secondly, the latest research progress of flame retardant PA66 was comprehensively reviewed, including blending, copolymerization and post–finishing flame retardant modification methods. Meanwhile, the research status of blending flame retardant PA66 was emphatically introduced, and the advantages and disadvantages of different additive flame retardants were analyzed. Finally, the future development direction of flame retardant PA66 is proposed, which provides an important reference for its follow-up study. Full article
(This article belongs to the Special Issue Polymer Manufacturing Processes)
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