Search Results (461)

Dynamic covalent bonds within polymer materials have been the subject of ongoing research. These bonds impart polymers, particularly thermosets, with capabilities for self-healing and reprocessing. Concurrently, three-dimensional (3D) printing techniques have undergone rapid advancement and widespread adoption. Since polymers are among the primary materials used in 3D printing, networks featuring dynamic covalent bonds have emerged as a prominent research area. This review outlines approaches for incorporating dynamic covalent bonds into polymers suitable for 3D printing and examines representative studies that leverage these chemistries in material design. Polymers produced using these strategies demonstrate both self-healing and reprocessability, primarily via bond-exchange (metathesis) reactions. In addition, we discuss how the type and amount of dynamic bonds in the network affect the resulting material properties, with particular emphasis on their mechanical, physical, and thermal performance. In particular, the introduction of dynamic covalent bonds seems to significantly improve the degree of anisotropy, which has been the limitation of 3D printing techniques. Finally, we compile recent applications for objects printed from polymers that include dynamic covalent bonds. Full article

Carbon Fiber-Reinforced Polymer (CFRP) composites, widely used across industries, exhibit various damage mechanisms depending on the loading conditions applied. This study employs a structural health monitoring (SHM) approach to investigate the three primary failure modes, fiber breakage, matrix cracking, and delamination, in thermoset quasi-isotropic CFRPs subjected to quasi-static tensile loading until failure. Acoustic emission (AE) signals acquired from an experiment were leveraged to analyze and classify these real-time signals into the failure modes using machine learning (ML) techniques. Due to the extensive number of AE signals recorded during testing, manually classifying these failure mechanisms through waveform inspection was impractical. ML, alongside ensemble learning, algorithms were implemented to streamline the classification, making it more efficient, accurate, and reliable. Conventional AE parameters from the data acquisition system and feature extraction techniques applied to the recorded waveforms were implemented exclusively as classification features to investigate their reliability and accuracy in classifying failure modes in CFRPs. The classification models exhibited up to 99% accuracy, as depicted by evaluation metrics. Further studies, using cross-correlation techniques, ascertained the presence of fiber break events occurring in the bundles as the thermoset CFRP composite approached failure. These findings highlight the significance of integrating machine learning into SHM for the early detection of real-time damage and effective monitoring of residual life in composite materials. Full article

In this study, the blends of bio-based polybenzoxazine (V-fa type) and poly(ethylene glycol) (PEG) with PEG contents from 50 to 95 wt% and different molecular weights were developed to improve the flexibility of thermosetting polymers. Of these blends, PEG 8k at 80 wt%, which exhibited the best processability, was selected for further development via compositing with carbon black (CB) from 0 to 20 phr. Differential Scanning Calorimetry (DSC) analysis revealed that the melting temperature (T_m) increased from 70 to 83 °C and glass transition temperatures (T_g) increased from –53 to –48 °C at 20 phr. Thermogravimetric Analysis (TGA) demonstrated high thermal stability, with T_dmax (for all CB contents) presented at ca. 416 °C. Moreover, char yield was increased from 10% (without CB) to 28% (20 phr), reflecting improved decomposition resistance. Mechanical properties demonstrated that CB significantly reinforced the composites. The flexural modulus and flexural strength were increased from 117.18 MPa (without CB) to 456 MPa (10 phr) and from 2.42 MPa (without CB) to 3.94 MPa (2.5 phr), respectively. The SEM images confirmed uniform morphology and good filler dispersion. Conclusively, the composites of 8k PEG 80 wt% filled with 2.5 phr of CB provided an optimal balance of mechanical and thermal stability and engineering polymer applications. Full article

Thermoset composites provide excellent strength but pose major recycling challenges due to their crosslinked structure. In this study, epoxy–polyurethane–glass fiber (EPG) wastes were mechanically recycled into low-density polyethylene (LDPE), high-density polyethylene (HDPE), and polyamide-6 (PA6) matrices to produce second-generation thermoplastic composites (STCs). Fillers at 10–50 wt% were processed by single-screw extrusion and compression molding, and the resulting composites were comprehensively characterized. For LDPE, the tensile modulus increased by ~286–589% and tensile strength increased by 40–47% at 20–30 wt% loading, though ductility decreased at higher levels. HDPE composites showed a ~347% rise in modulus and ~24% increase in strength, but performance declined with more than 40 wt% filler. PA6 offered the most balanced outcome, retaining ~70% of its neat tensile strength while achieving an ~300% modulus improvement at 40 wt% loading. Thermal stability was strongly enhanced, with char residue at 700 °C rising from 0.4% to 38.7% in PA6 and from ~2.5% to 33–46% in polyolefins. In contrast, crystallinity decreased (e.g., LDPE 62.2% → 23.7%), and impact strength dropped at a loading above 30 wt%. Overall, the results demonstrate that EPG wastes can be reprocessed into functional composites without compatibilizers, with PA6 providing the most robust property retention at high filler contents. Full article

Pultrusion is a manufacturing process used to produce fiber-reinforced polymer composites with excellent mechanical, thermal, and chemical properties. The resulting materials are lightweight, durable, and corrosion-resistant, making them valuable in aerospace, automotive, construction, and energy sectors. However, conventional thermoset composites remain difficult to recycle due to their infusible and insoluble cross-linked structure. This review explores integrating vitrimer technology a novel class of recyclable thermosets with dynamic covalent adaptive networks into the pultrusion process. As only limited studies have directly reported vitrimer pultrusion to date, this review provides a forward-looking perspective, highlighting fundamental principles, challenges, and opportunities that can guide future development of recyclable high-performance composites. Vitrimers combine the mechanical strength (tensile strength and modulus) of thermosets with the reprocessability and reshaping of thermoplastics through dynamic bond exchange mechanisms. These polymers offer high-temperature reprocessability, self-healing, and closed-loop recyclability, where recycling efficiency can be evaluated by the recovery yield retention of mechanical properties and reuse cycles meeting the demand for sustainable manufacturing. Key aspects discussed include resin formulation, fiber impregnation, curing cycles, and die design for vitrimer systems. The temperature-dependent bond exchange reactions present challenges in achieving optimal curing and strong fiber–matrix adhesion. Recent studies indicate that vitrimer-based composites can maintain structural integrity while enabling recycling and repair, with mechanical performance such as flexural and tensile strength comparable to conventional composites. Incorporating vitrimer materials into pultrusion could enable high-performance, lightweight products for a circular economy. The remaining challenges include optimizing curing kinetics, improving interfacial adhesion, and scaling production for widespread industrial adoption. Full article

Cross-linked polymers are indispensable in advanced applications, but suffer from poor recyclability due to permanent covalent networks. Herein, we report recyclable supramolecular polyurea elastomers that integrate ureidopyrimidinone-based quadruple hydrogen-bonding motifs directly into the polymer backbone. The dynamic and reversible nature of these motifs imparts the SPUEs with remarkable malleability and reprocessability while preserving the robustness of conventional polyureas. The SPUEs display remarkable mechanical robustness, solvent resistance, and facile reprocessability through hot-pressing, producing homogeneous films with minimal performance loss. Impressively, tensile strength, elongation at break, and toughness retained high recovery after reprocessing, demonstrating excellent closed-loop mechanical recyclability. This work showcases supramolecular engineering as a powerful strategy to reconcile mechanical robustness with recyclability in cross-linked polymers, offering new opportunities for sustainable thermosets and elastomers in circular materials design. Full article

As the importance of sustainability and performance increases, new developments in the manufacturing of fiber-reinforced polymer composites (FRPC) are requested. Ultraviolet (UV) curing offers a faster, more economical, and eco-friendlier alternative to conventionally used thermal curing methods, e.g., autoclave curing, but according to extant research, also presents some shortcomings, such as limitations to thin FRPCs and transparent glass fibers (GFs). This study analyses the UV light transmission in different thermoset FRPCs by irradiating various fiber samples on one side, while a sensor on the opposite side measures the transmitted irradiance. The materials investigated include unidirectional (UD) carbon fibers (CF), UD flax fibers (FF), and six GF fabrics with different ply structures. The fiber samples are tested in a dry, non-impregnated state and a resin-impregnated state using a UV-curable vinyl-ester-based resin. The results show that up to 16 plies of five GF fabrics are fully cured within the 20 s irradiation time and still exhibit a relatively high light transmission, revealing the potential of curing thick FRPCs with UV light. Furthermore, up to three plies of non-transparent FFs are cured, which is promising for the UV curing of natural fibers. Full article

This publication presents an improved manufacturing method for tetrahedral metal effect pigment particles that demonstrates reduced flowlines in injection-molded polymer components compared with conventional platelet-shaped pigment particles. The previously published cold forming process for tetrahedral particles, made entirely from aluminum, faced manufacturing challenges, resulting in a high reject rate due to particle adhesion to the micro-structured mold roller. In contrast, this study introduces a new manufacturing method for tetrahedral particles, now consisting of metallized UV-cured thermoset polymer. These particles, dispersed in amorphous matrix thermoplastics, have shown to maintain their shape during the injection molding process. The manufacturing technique for these novel particles is based on UV imprint lithography, omitting the reject rates compared with the previously presented cold rolling process of tetrahedral full aluminum particles. Thus, the novel manufacturing technique for tetrahedral pigment particles shows increased potential for automation through roll-to-roll manufacturing in the future. Full article

The rheological behavior and low-temperature curing kinetics of poly(ethylene glycol fumarate)–acrylic acid systems initiated by benzoyl peroxide/N,N-dimethylaniline have been investigated for the first time with a focus on the development of thermosetting binders with controllable properties. It has been established that both composition and temperature have a significant effect on rheological behavior and kinetic parameters. Rheological studies revealed non-Newtonian flow behavior and thixotropic properties, while oscillatory tests demonstrated structural transformations during curing. Increasing the temperature was found to accelerate gelation, whereas a higher polyester content retarded the process, which is crucial for controlling the pot life of the reactive mixture. DSC analysis indicated that isothermal curing at 30–40 °C can be satisfactorily described by the Kamal autocatalytic model, whereas at 20 °C, at later stages, and at higher polyester contents, diffusion control becomes significant. The thermal behavior of cured systems was investigated using thermogravimetry. Calculations using the isoconversional Kissinger–Akahira–Sunose and Friedman methods confirmed an increase in the apparent activation energy for thermal decomposition, suggesting a stabilizing effect of poly(ethylene glycol fumarate) in the polymer structure. The studied systems are characterized by controllable kinetics, tunable viscosity, and high thermal stability, making them promising thermosetting binders for applications in composites, construction, paints and coatings, and adhesives. Full article

Wind power is integral to the transformation of energy systems towards sustainability. However, the increasing number of wind turbines approaching the end of their service life presents significant challenges in terms of waste management and environmental sustainability. Rotor blades, typically composed of thermoset polymer composites reinforced with glass or carbon fibres, are particularly problematic due to their low recyclability and complex material structure. The aim of this article is to provide a system-level review of current end-of-life strategies for wind turbine components, with particular emphasis on blade recycling and decision-oriented comparison, and its integration into circular economy frameworks. The paper explores three main pathways: operational life extension through predictive maintenance and design optimisation; upcycling and second-life applications; and advanced recycling techniques, including mechanical, thermal, and chemical methods, and reports qualitative/quantitative indicators together with an indicative Technology Readiness Level (TRL). Recent innovations, such as solvolysis, microwave-assisted pyrolysis, and supercritical fluid treatment, offer promising recovery rates but face technological and economic as well as environmental compliance limitations. In parallel, the review considers deployment maturity and economics, including an indicative mapping of cost and deployment status to support decision-making. Simultaneously, reuse applications in the construction and infrastructure sectors—such as concrete additives or repurposed structural elements—demonstrate viable low-energy alternatives to full material recovery, although regulatory barriers remain. The study also highlights the importance of systemic approaches, including Extended Producer Responsibility (EPR), Digital Product Passports and EU-aligned policy/finance instruments, and cross-sectoral collaboration. These instruments are essential for enhancing material traceability and fostering industrial symbiosis. In conclusion, there is no universal solution for wind turbine blade recycling. Effective integration of circular principles will require tailored strategies, interdisciplinary research, and bankable policy support. Addressing these challenges is crucial for minimising the environmental footprint of the wind energy sector. Full article

A novel quinoline-containing benzoxazine resin, 8HQ-fa, has been successfully synthesized at room temperature using sustainable raw materials, such as 8-hydroxyquinoline and furfurylamine as the phenol and amine source, respectively. The chemical structure of the hereinafter referred to as quinolinoxazine is fully characterized by Fourier transform infrared spectroscopy (FT-IR), ¹H and ¹³C nuclear magnetic resonance spectroscopy (NMR), as well as by 2D ¹H–¹H nuclear Overhauser effect spectroscopy (NOESY) and ¹H–¹³C heteronuclear multiple quantum correlation (HMQC) NMR. Thermal properties and polymerization behavior of the monomer are studied by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The resulting polymer is also characterized in terms of its thermal and fire-related properties by DSC, TGA, and microscale combustion calorimetry (MCC). The resulting thermoset, poly(8HQ-fa), presents good thermal stability as evidenced by its T_g (201 °C), T_d5 and T_d10 (307 and 351 °C, respectively), and char yield (42%), and low flammability as determined by the LOI, heat release capacity, and total heat released values (34.3, 143 J/gK, and 10.8 kJ/g, respectively), making it a self-extinguishing thermoset. The combination of properties and advantages in the synthesis of 8HQ-fa, accompanied by a low polymerization temperature, suggests its great potential in the field of high-performance polymers. Full article

In recent years, efforts have focused on developing repairable, malleable, and recyclable thermoset materials to reduce the growing volume of polymer waste and extend the lifetime of existing polymeric materials. Specifically, associative covalent adaptable networks (CANs), also known as vitrimers, have received considerable attention. In this work, photopolymerizable vitrimers were prepared by combining crosslinkers containing β-amino esters in their structure with hydroxylated acrylate or methacrylate monomers, with the aim of reprocessing these materials through the activation of transesterification reactions. The network design and photopolymerization conditions were optimized to ensure the successful formation of the vitrimers. Tunable mechanical and thermal properties were achieved by varying their chemical composition. Furthermore, the reprocessing ability of these materials was confirmed through thermal treatments. Additionally, these vitrimers exhibited the ability to undergo hydrolysis in basic aqueous media, providing an alternative pathway for recycling. Full article

This review paper explores the transformative potential of polymer composites and adhesives in reducing the weight of aircraft landing gear, thereby improving fuel efficiency and lowering emissions. The replacement of conventional metallic materials and mechanical fastenings with advanced thermoset/thermoplastic composites and adhesives can significantly enhance durability and performance in demanding operational environments. Unlike traditional fastening methods, the structural adhesives eliminate the weight penalties associated with mechanical fasteners, offering a lighter and more reliable solution that meets the rigorous demands of modern aerospace engineering. Furthermore, the review highlights a variety of manufacturing techniques and innovative materials, including bio-based polymers, self-healing materials, noobed composites, helicoid composites, and hybrid composites. The use of thermosets and vitrimers in adhesive bonding are presented, illustrating their ability to create robust and durable joints that enhance the structural integrity of landing gear systems. The paper also addresses current challenges, including recycling limitations and high material costs. Sustainability considerations, including the integration of self-healing materials, structural health monitoring systems, and circular economy principles, are discussed as essential for aligning the aerospace sector with global climate goals. Full article

Driven by the growing demand for sustainable materials, spent coffee grounds have emerged as a promising bio-based reinforcement in polymer composites, particularly for additive manufacturing applications. As a readily available byproduct of the coffee industry, spent coffee grounds contain cellulose, hemicellulose, lignin, proteins, and oils, making them attractive fillers for both thermoplastic and thermoset matrices. Incorporating spent coffee grounds into composites supports waste valorization, cost reduction, and environmental sustainability by transforming organic waste into functional materials. This review first examines the issue of spent coffee ground waste, addressing its environmental footprint and disposal challenges. It then explores the composition and properties of spent coffee grounds. The paper provides a comprehensive overview of composites based on spent coffee grounds for 3D printing, covering processing methods, potential applications, and current challenges in additive manufacturing. Special attention is given to the preparation and processing of these composites, including key steps such as drying, grinding, sieving, and surface modification to enhance compatibility with polymer matrices. Various additive manufacturing techniques influence the printability, processability, and mechanical performance of such composites. While spent coffee grounds offer notable sustainability advantages, challenges such as weak interfacial adhesion, moisture sensitivity, and reduced mechanical properties necessitate optimized processing conditions, surface treatments, and tailored material formulations. This review highlights recent advancements and outlines future research directions, emphasizing the need for stronger interactions between spent coffee grounds and polymer matrices, improved recyclability, and scalable additive manufacturing solutions to establish spent coffee grounds as a viable and eco-friendly alternative for 3D printing applications. Full article

Over the last few decades, polymer composites have been rapidly making inroads in critical applications of electrical storage devices such as batteries and supercapacitors. Structural supercapacitor composites (SSCs) have emerged as multifunctional materials capable of storing energy while bearing mechanical loads, offering lightweight and compact solutions for energy systems. This study investigates the functionalization of Bisphenol A-based thermosetting polymers with ionic liquids, aiming to synthesize dual-functional structural electrolytes for SSC fabrication. A multifunctional sandwich structure was subsequently fabricated, in which the fabricated SSC served as the core layer, bonded between two structurally robust outer skins. The core layer was fabricated using carbon fibre layers coated with 10% graphene nanoplatelets (GNPs), while the skin layers contained 0.25% GNPs dispersed in the resin matrix. The developed device demonstrated stable operation up to 85 °C, achieving a specific capacitance of 57.28 mFcm⁻² and an energy density of 179 mWhm⁻² at room temperature. The performance doubled at 85 °C, maintaining excellent capacitance retentions across all experimented temperatures. The flexural strength of the developed sandwich SSC at elevated temperature (at 85 °C) was 71 MPa, which exceeds the minimum requirement for roofing sheets as specified in Australian building standard AS 4040.1 (Methods of testing sheet roof and wall cladding, Method 1: Resistance to concentrated loads). Finite element analysis (FEA) was performed using Abaqus CAE to evaluate structural integrity under mechanical loading and predict damage initiation zones under service conditions. The simulation was based on Hashin’s failure criteria and demonstrated reasonable accuracy. This research highlights the potential of multifunctional polymer composite systems in renewable energy infrastructure, offering a robust and energy-efficient material solution aligned with circular economy and sustainability goals. Full article