Browse Topic: Thermoplastics

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Development and Technical Verification of A Lunar Dust Environment Simulation Mechanism2026-99-01757/31/2026
Lunar dust consists of extremely fine particles and exhibits electrostatic charging properties and electrostatic adhesion. These characteristics cause lunar dust to be highly susceptible to mobilization during lander touchdowns, rover traversals, and human activities, forming widely distributed dust clouds. Lunar dust contamination not only abrades spacecraft and equipment to impair their performance but also poses a threat to astronauts’ safety. To verify the impact of the lunar dust environment on exploration equipment components, a simulation mechanism adaptable to the thermal vacuum test environment was designed. This mechanism is integrated into the lunar environment simulation system and uses a vacuum stepper motor to drive a ratchet mechanism, enabling precise vibrational injection of simulated lunar dust. It mainly consists of a pretreatment mechanism, a particle sedimentation mechanism, a shielding mechanism, and an ultraviolet (UV) irradiation system. Considering the vacuum operating environment, alternating high and low temperature conditions, as well as the strict requirements for the mechanism’s compact size and high reliability, this paper analyzes in detail a series of problems encountered during the development of the mechanism and their corresponding solutions. Stainless steel and polytetrafluoroethylene (PTFE) were selected as the main materials for the mechanism. Meanwhile, active temperature control measures were adopted to actively regulate the temperature of components such as the motor. Ultimately, the mechanism can withstand alternating high and low temperatures ranging from -150°C to 150°C and a vacuum environment of 5 × 10^–6 Pa. Under this environment, the mechanism can achieve vibration frequency adjustment within the range of 1-5 Hz, and realize the sedimentation of simulated lunar dust particles with a particle size of less than 200 μm over an area of 150 mm × 150 mm. After sedimentation, the simulated lunar dust particles can be charged through the photoelectric effect.
Xu, Menglong, Lv, Shizeng, Li, Guohua, Gong, Jie
Screen-Printed Flexible Sensor for Conveyor Belt Fault Monitoring2026-99-01957/31/2026
Conveyor belt fault detection is critical for ensuring the safety and efficiency of industrial material transportation. In this study, a screen-printed flexible strain sensor based on a thermoplastic polyurethane (TPU) substrate and graphene conductive ink was fabricated. The sensor exhibited excellent flexibility, mechanical robustness, and stable electromechanical performance. Comprehensive evaluations were conducted, including microstructural analysis, strain sensitivity, hysteresis, dynamic response, and long-term cycling stability. The results demonstrated that a two-layer graphene configuration achieved an optimal balance between sensitivity and structural stability, showing high gauge factor, fast response, and reliable cyclic performance. Furthermore, the sensor was applied to conveyor belt fault monitoring. Experiments validated its ability to detect both halting faults and foreign object intrusions, with distinctive resistance signal features enabling not only fault occurrence detection but also identification of fault location, type, and severity. These findings highlight the potential of the proposed flexible sensor system as a promising solution for intelligent conveyor belt monitoring in harsh industrial environments.
Zhang, Bo, Ai, Shigeng, Zhang, Xiaobo, Sun, Wanting, Li, Pengfei
Test and Simulation Analysis of Edgewise Compressive Performance of Marine Composite Sandwich Structures with Delamination Defects2026-99-02007/31/2026
In this paper, PTFE membranes were used to preform delamination defects, and VARI technology was employed to prepare marine composite sandwich structures with such defects. The cohesive zone model was used to emulate the interfacial bonding characteristics, thereby establishing a simulation analysis model to assess the edgewise compressive behavior of marine composite sandwich structures with delamination discontinuities. By combining experimental data with simulation results, the edgewise compressive resistance of marine composite sandwich structures was evaluated. Additionally, various parameters including the size, depth, quantity, and geometry of the delamination defects were studied to investigate their effects on the edgewise compressive performance of the marine laminated structures. The research results indicate that as the number of delamination defects increases, the edgewise compressive strength of the sandwich structure gradually decreases. Particularly, when the diameter of the layering defect is less than 30 millimeters, the influence of the defect on the edgewise compressive strength of the sandwich structure can be negligible. Conversely, when the diameter of the defect exceeds 30 millimeters, the rate of decrease in edgewise compressive strength increases significantly with the increase in the diameter of the defect, thereby greatly exacerbating the adverse effects of the delamination defects and ultimately resulting in a 10.77% reduction in the edgewise compressive strength. Furthermore, it was observed that the delamination defects located at the interface between the two panels and the core material on both sides of the sandwich structure do not affect each other, and to a certain extent, improve the compressive stability of the specimen. The degree of edgewise compressive strength reduction caused by elliptical delamination defects with the same area and long axis length is less than that of corresponding circular delamination defects, indicating that using circular delamination defects in the analysis of composite material structures with delamination defects is safer.
Zhang, Yao, Xu, Mingcai, Bian, Tianya, Zhou, Songqiang, Ji, Bing, Cheng, Jiahuan, Zhuang, Ya, Li, Xiang
Tailored Thermo-Mechanical Behaviour of CNT/Epoxy Nanocomposites via Solvent-Assisted Dispersion2026-99-01897/31/2026
Carbon nanotube (CNT) reinforced epoxy nanocomposites were prepared using a solvent-assisted dispersion method and characterized to evaluate their structural, mechanical, and thermal behaviour. X-ray diffraction (XRD) confirmed the presence of CNTs in the polymer matrix through the characteristic (002) reflection, while scanning electron microscopy (SEM) revealed that CNTs were found to be uniformly embedded within the epoxy matrix, showing limited agglomeration and strong interfacial bonding. Fourier-transform infrared spectroscopy (FTIR) supported these observations by revealing absorption bands associated with C=C stretching, C–O–C ether linkages, and O–H vibrations, indicating chemical interactions between CNTs and the epoxy network. Mechanical testing showed that CNT concentrations of 0.25–0.50 wt.% provided the most effective reinforcement, with notable and measurable improvements in tensile and compressive strength as well as modulus. At higher CNT loadings, however, agglomeration led to reduced tensile performance, despite compressive strength remaining comparatively stable. Thermal conductivity increased steadily with CNT addition, from 0.2143 W/m.K for neat epoxy to 0.2435 W/m.K at 0.75–1.00 wt.%, with the most pronounced improvements observed above 0.25 wt.% due to the formation of more efficient conductive pathways. Overall, these findings suggest that low-to-intermediate CNT loadings achieve a practical and useful balance between strength and thermal conductivity while avoiding the drawbacks of excessive filler content. Effective dispersion of nanotubes is a critical factor that governs the mechanical and thermal behaviour of the composites. These results indicate that CNT/epoxy nanocomposites produced under optimized conditions can serve as lightweight, mechanically reliable, and thermally stable materials, making them attractive candidates for advanced applications in aerospace, automotive, and energy-related sectors where both structural performance and efficient thermal management are required.
Gul, Aysenur, Kamali, Ali Reza
Application of a Novel Noise-Reduction Material to Reduce Squeak Noise in Automotive Instrument Panels2026-01-50657/31/2026
In recent years, driven by increasing consumer demands for vehicle aesthetics and perceived quality, automotive instrument panels (IPs) have extensively adopted materials with poor friction compatibility, such as chrome-plated strips and synthetic leather. Concurrently, the engineering requirement for tighter matching gaps between components has significantly escalated the risk of friction noise. Traditional mitigation strategies—such as material substitution, increasing gap clearances, or applying physical isolation—are often difficult to implement due to design constraints, rendering the IP a critical high-risk zone for abnormal noise. This paper proposes a methodology to mitigate squeak noise between polycarbonate/acrylonitrile butadiene styrene (PC/ABS) and its mating counterparts by modifying the viscoelastic characteristics of the PC/ABS base material through the addition of a specialized polymer. Furthermore, a neural network model was established to objectively determine the noise compatibility of these materials. Evaluations of the material compatibility before and after modification demonstrate that adding a specific proportion of the special polymer to PC/ABS significantly improves its friction compatibility with materials such as polyvinyl chloride (PVC) skin. The efficacy of this solution was confirmed through application and verification in a mass-production vehicle.
Liu, Zubin, Cao, Chunyu, Hou, Hangsheng
Improvement of rCF Behaviour through the Introduction of NF2026-37-00396/9/2026
This study investigates the structural improvement of recycled carbon fibre composites through hybridisation with continuous flax fibres to address sustainability concerns and performance limitations. Recycled carbon fibres, while environmentally beneficial, suffer from short, randomized orientations and lower mechanical properties limiting their application beyond decorative uses. This research explores whether incorporating unidirectional flax fibres can enhance rCF behaviour for structural applications. Six hybrid composite layup variants and two plain composites were manufactured using cold compression moulding with Ampro Bio Resin. Each hybrid configuration comprised eight layers, divided into four layers of recycled carbon and four layers of flax fibres oriented at 0°. Complete mechanical characterization was performed following ISO standards for tensile (ISO 527), flexural (ISO 178), and impact (ISO 179) testing. Results demonstrated significant performance improvements in hybrid composites. Among hybrids, layup 2 achieved 212.5 MPa tensile strength whilst layup 3 managed to achieve 20.5 GPa in stiffness. Flexural testing revealed layup 6 achieved the highest flexural modulus of 19.6 GPa among hybrids. Impact resistance improved dramatically with layup 3 demonstrating 186% improvement in energy absorption over recycled carbon fibre. The study confirms that hybridisation creates a positive effect, producing more predictable and durable materials. The complementary behaviour between brittle and ductile materials enhances damage tolerance and structural integrity, establishing a foundation for sustainable engineering materials suitable for automotive applications without compromising reliability.
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
Development of Graphene Filled Polypropylene Nanocomposite for Aerospace Application2026-26-07396/1/2026
Polypropylene, a commodity plastic, is the semi-crystalline thermoplastics widely used in high volume for general purpose application. Polypropylene is the macro molecules of soft and weak backbone, which by reinforcement of fillers in different forms such as fiber, spheroids, nanotubes, flakes, etc., can influence its mechanical, thermal, electrical, creep resistance, and flame resistance properties for use in aerospace applications. Currently, polycarbonate and nylon plastics are used in aerospace applications, however, they are expensive compared with polypropylene. In this thesis, efforts are put to study the effect of reinforcement fillers in the properties of polypropylene composite, primarily the mechanical and flammability properties. The matrix element, polypropylene co polymer and reprocessed polypropylene blended in equal ratio, are coupled with the dispersing phases such as graphene, mica, fumed silica, and polydimethylsiloxane polymer. Effect of graphene as reinforcing filler at different weight % to polypropylene composite’s properties are studied and compared with that of the neat polypropylene. Effect of coupling agent, Aminopropyltriethoxysilane (APTES), on mineral fillers and Polydimethylsiloxane polymer (PDMS) used for crosslinking with the polypropylene matrix is also studied and compared using Fourier Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscope (SEM) techniques.
Govindaraju, Parthasarathy
Polyamide AerogelsTBMG-552896/1/2026
Sometimes referred to as “solid smoke,” aerogels are the world’s lightest solid materials, composed of approximately 85 percent air by volume. Polyamide aerogels open up a whole new world of applications due to their unique properties: translucent like silica aerogels; thermoplastic; ultra-low density; superior mechanical properties; low-temperature operating range; and highly flexible (as compared to NASA Glenn’s polyimide aerogels). Polyamide aerogels are further novel because of their tunable glass transition temperatures, meaning that crystallinity, and hence strength, can be controlled via operating temperature. Addressing the key drawbacks of aerogel technology (hydroscopicity, fragility, cost), NASA Glenn’s suite of organic aerogels are cost-competitive with both existing silica aerogels and, with scale-up, high-end foamed polymer insulation.
Researchers Turn Recovered Car Battery Acid and Plastic Waste Into Clean HydrogenTBMG-552586/1/2026
Researchers have developed a solar-powered reactor to break down hard-to-recycle forms of plastic waste – such as drinks bottles, nylon textiles and polyurethane foams – using acid recovered from old car batteries, and converting it into clean hydrogen fuel and valuable industrial chemicals.
Multiphysics Modeling and Performance Assessment of Ultrasonic Welding for Thermoplastic CompositesF-0082-2026-01205/5/2026
Ultrasonic welding (UW) provides a rapid and efficient method for joining composite components by inducing resin flow through thermally driven diffusion and crystallization at the bonded interface. However, in the absence of a multiphysics modeling framework or a digital twin approach, current practice still depends on extensive trial-and-error testing to determine key welding parameters such as vibration amplitude, weld time, weld pressure, hold time, and downspeed. While in-situ thermal cameras can monitor surface temperatures, the internal temperature at the bonded interface is often significantly higher, introducing the risk of thermal degradation and inconsistent bond quality. To overcome these limitations, GEM developed a high-fidelity multiphysics model to establish a quantitative relationship between process parameters and the evolving temperature field within welded thermoplastic parts. The model integrates coupled mechanical, thermal, and acoustic physics to simulate high-frequency vibrations and static pressure, capture the generation and spatial distribution of heat, and represent the temperature-dependent viscoelastic response that governs bond formation. A validation test matrix was designed by systematically varying weld time and vibration amplitude. Through-thickness temperature distributions were measured using infrared thermal imaging, enabling direct comparison with model predictions. Upon validation, the model was applied for process tailoring, allowing precise control of temperature distribution to achieve target bond strength. This integrated modeling and validation approach demonstrated substantial benefits, including reduced design iterations, accelerated process optimization, and improved quality and performance of welded composite structures.
Walthers, Mark, Li, Rui, Wei, Qingxuan, Lua, Jim
Design, Manufacturing, and Testing of Rotor Blades with Flax Fiber-Reinforced Composites and 3D-Printed CoresF-0082-2026-02655/5/2026
This paper investigates the feasibility of using flax fiber-reinforced composites in combination with additively manufactured polymer cores for helicopter rotor blades. A new rotor blade with flax composite spar and skin laminates and a 3D-printed ASA Aero core was designed to be geometrically equivalent to an existing carbon fiber/foam reference blade of the MERIT rotor test rig and manufactured using identical tooling. Material characterization included compression testing of the printed core at ambient and elevated temperatures, single-lap shear adhesion testing with epoxy laminates, and hygroscopic conditioning of core and laminate specimens. Structural testing comprised static beam bending, experimental modal analysis with axial pre-loading to approximate centrifugal stiffening, and sustained-load creep and recovery testing of the flax blade. The results show that the 3D-printed core provides sufficient compressive stiffness at curing temperature and adhesion to epoxy laminates, enabling its use as an internal consolidation tool during blade manufacturing. Compared to the carbon reference blade, the flax/3D blade exhibits reduced flapwise and lead–lag bending stiffness, altered modal behavior, and pronounced viscoelastic effects, including creep, incomplete recovery, and strong hygroscopic swelling. Component-level hygroscopic tests reveal that moisture-induced mass and thickness changes can generate sufficient internal stresses to locally initiate structural damage. Overall, the study identifies key limitations and design considerations for applying flax fiber composites in primary rotor blade structures.
Gaugelhofer, Lukas, Yavrucuk, Ilkay
Resilient Nylon Device Creates Electricity Under Tons of PressureTBMG-550645/1/2026
Certain materials — such as quartz, some ceramics, and even bone — produce an electrical charge when they are squeezed, pressed, or vibrated. This is piezoelectricity, which comes from the Greek “piezein” meaning to press. Modern vehicles rely on piezo components in fuel injectors, parking sensors, airbag systems, and other functions.
How Electroadhesion Can Hold Materials TogetherTBMG-550885/1/2026
Is there a way to stick hard and soft materials together without any tape, glue, or epoxy? A new study published in ACS Central Science shows that applying a small voltage to certain objects forms chemical bonds that securely link the objects together. Reversing the direction of electron flow easily separates the two materials. This electroadhesion effect could help create biohybrid robots, improve biomedical implants, and enable new battery technologies.
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy composite using an in-house SHPB powered by a compressed gas gun and equipped with a high speed DAQ (data acquisition) system. A unique feature of the current study is the reporting of stress-strain curves at high strain rates when specimens are loaded in off-axis directions i.e. at angles to the principal direction (viz. 0°, 15°, 30°, etc.). The results highlight the substantive effect of strain rate on properties such as failure strength of the considered composite, and its visibly distinct behaviors in various off-axis loading directions.
Bawa, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-02484/7/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as increased cargo space by taking advantage of EPP parts with thinner cross-sections. Using current production equipment, testing was conducted on physical parts through real-time molding trials with measurements and analysis to confirm the improvements in tolerance and performance described above. Incorporating these findings early in the design phase of a given application will allow automotive engineers to fully leverage these benefits, ensuring optimal part integration, system-level performance, and alignment with corporate sustainability goals.
Sopher, Steven, Parker, Joshua
Simplified Thermal Runaway Propagation Modeling to Design a Mass Optimized Battery Pack2026-01-04044/7/2026
This paper presents a simplified approach to model thermal runaway propagation in a multi-cell battery pack, with the goal of designing a safe and lightweight pack for mass-sensitive applications. The key parameters which characterize single-cell thermal runaway, including heat release profile, apparent cell emissivity and mass loss, were extracted from empirical nail penetration tests. This characterization was used to drive a three-dimensional thermal model of a 19-cell hexagonal sub-pack with a center trigger cell. To enable rapid design exploration, a symmetry-based computationally simplified domain was used for a full-factorial Design of Experiments (DOE) varying cell spacing, epoxy thickness, heat spreader thickness, and cup geometry. The DOE results were used to identify dominant heat-transfer mechanisms, capture main and interaction effects, and determine mass-efficient design levers governing peak-neighbor cell temperature during propagation. Insights from the DOE study informed the design of a physical prototype and the placement of thermocouples for model validation. Measured temperature data showed good agreement with model predictions across multiple initiator locations, with 4–7 °C error in peak temperature and 3–5 s error in time to reach peak temperature. However, accurate reproduction of the observed trends required increasing epoxy thermal conductivity on the initiator cell to represent epoxy carbonization observed during post-test teardown. This simplified modeling approach, paired with targeted testing, can provide practical design guidance, reduce overall testing cost, and enable fast development of mass-optimized, propagation-resistant battery packs.
Kalyankar, Apoorv, Owen, Elliot, Strohmaier, Kyle, Mardall, Joseph
Characterization of a Low-Cost Insulator Substrate for Traction Power Modules2026-01-01194/7/2026
Demand for cost-effective automotive traction inverters requires improved power module packaging. This paper presents a packaging method using an epoxy composite insulator applied directly to the cold plate surface, replacing Direct Bonded Copper (DBC) and Active Metal Brazed (AMB) substrates. This integration removes the substrate-to-cold plate solder interface and eliminates two material layers from the thermal path. The epoxy composite demonstrates a dielectric strength greater than 60 kV/mm. Thermal resistance (junction-to-coolant) measured approximately 0.17 K∙cm2/W. Electrical characterization showed a relative permittivity of 3.9, which is lower than standard ceramics and results in reduced parasitic capacitance. Initial thermal cycling tests indicated no significant degradation in thermal or electrical performance. These results suggest the epoxy composite insulator could be a promising alternative for traction power modules.
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
NASA Tech Briefs: April 202626AERP044/2/2026
Leonardo DRS Expands Production Capacity to Advance Naval Power, Sensors, and AI-Driven Mission Systems Success at Sea: NIWC Atlantic Uncrewed Surface Vessel Completes Fastest Transatlantic Crossing High‑Speed Spindles Unlock Five‑Axis Machining Innovation with Smaller Tools Why CFD is Stuck in the File Era Accurate and Resilient GNSS Timing Modules for Critical Infrastructure Undetectable Ship-to-Ship Laser Communications EP40: Structural Epoxy Used for Steel Bonding in Marine Applications Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry Vortex Research to Solve Aviation's Efficiency Tradeoff with Active Strakes A research team developed a smart strake system that dynamically adapts to flight conditions, showing a promising drag reduction in the wind tunnel with respect to passive strakes. This approach has the potential to save airlines hundreds of kilograms of fuel per flight. New 3D-Printing and Manufacturing Techniques Grant More Control Over Energetic Material Behavior A newly developed tool could enable more control over how energetic materials function throughout manufacturing processes.
EP40: Structural Epoxy Used for Steel Bonding in Marine Applications26AERP04_074/1/2026
Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry. Master Bond Inc., Hackensack, NJ To reduce its environmental impact and pollution, the shipping industry is investigating methods to construct more lightweight ships. One potential method is using adhesive bonding techniques to replace traditional welding and riveted joints on ships to fabricate lighter ships with smaller carbon footprints. However, adhesives age and deteriorate when exposed to moisture, high temperatures, and ultraviolet light. This makes it necessary to understand how they age in maritime environments to determine whether they can truly replace traditional welding techniques. To this end, researchers at Centro de Investigación en Tecnologías Navales e Industriales (CITENI) and Centro de Investigación TIC (CITIC) developed a new method for studying adhesive aging on naval steel substrates. Master Bond EP40 was selected as the test adhesive for this method due to its strong performance and suitability for marine conditions. By using EP40, the team ensured that the observed adhesive bonding behavior would reflect a high-quality epoxy's potential in ship structures. The goal was to evaluate how EP40 bonds to naval steel and how the bulk epoxy material would behave in seawater to provide insights into the construction of lighter ships using this approach.
EP40: Structural Epoxy Used for Steel Bonding in Marine ApplicationsTBMG-549274/1/2026
To reduce its environmental impact and pollution, the shipping industry is investigating methods to construct more lightweight ships. One potential method is using adhesive bonding techniques to replace traditional welding and riveted joints on ships to fabricate lighter ships with smaller carbon footprints. However, adhesives age and deteriorate when exposed to moisture, high temperatures, and ultraviolet light. This makes it necessary to understand how they age in maritime environments to determine whether they can truly replace traditional welding techniques.
Sheet, Polychlorotrifluoroethylene (PCTFE), Molded, UnplasticizedAMS3646E (Current)3/25/2026
This specification covers a 100% homopolymer of polychlorotrifluoroethylene (PCTFE) in the form of molded sheet 0.250 inch (6.35 mm) and under in nominal thickness.
AMS P Polymeric Materials Committee
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a balanced response and Plate 3 demonstrated higher stiffness but lower damping capability. These findings suggest that incorporating areca Fiber in combination with E-glass not only reduces weight but also improves damping without significantly compromising structural integrity. The developed hybrid composites hold strong potential for lightweight, vibration-sensitive applications such as automotive interiors, marine structures, construction panels, and sports equipment, where both sustainability and performance are critical.
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Specialty Thermoplastics for Medical Tubing Address PFAS, Processing, and System Cost ChallengesTBMG-545292/1/2026
The global medical tubing market is enjoying strong growth, with analysts forecasting compound annual growth rates (CAGR) ranging from 6 to 9 percent over the next several years. Demand is being propelled by more-frequent or extended treatments for cancers and chronic diseases; increases in minimally or noninvasive surgery, home-based care, and patient wearables; and innovations such as sensor-enabled smart catheters and other advanced tubing applications.
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical behavior in injection-molded thermoplastic components, incorporating material anisotropy. The simulation results demonstrate that anisotropic modeling effectively captures the influence of short fiber orientations, revealing localized stress distributions and macroscopic failure indicator results. Outcomes of the current approach are compared with isotropic simulations that exclude injection molding data, highlighting the advantages of incorporating process-induced anisotropy. These findings enhance understanding of the mechanical performance of short fiber-reinforced thermoplastics and provide a foundation for future integration of multi-scale finite element tools. The application of this methodology supports the development of cost-effective and efficient virtual product designs by accurately predicting deformation and failure under various loading conditions.
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
New Generation Natural Rubber-Based Bump Stopper with Improved NVH Characteristics2026-26-02921/16/2026
In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria. Traditionally, Natural rubber (NR) has traditionally been favored for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. This study revisits NR with the goal of re-establishing its viability by enhancing its performance to match or surpass that of PU. Through compound optimization and advanced material processing techniques, significant improvements have been achieved in NR’s mechanical strength, compression set resistance, and environmental durability. Also a convolute bump stopper design was explored to enhance energy absorption and packaging efficiency. Compared to traditional solid profiles, the convoluted geometry provided progressive stiffness characteristics, improved deformation control, and optimized ride comfort under dynamic loading conditions. Traditional NR design and formulation were compared against PU and next-generation NR in terms of Aging Durability Factor, stiffness, fatigue durability, vehicle-level buzz, squeak, and rattle (BSR), as well as ride and handling performance. A comparative assessment of carbon emissions between PU and NR was also conducted to evaluate environmental impact. The result is a next-generation NR formulation that delivers performance comparable to PU while retaining the ecological and economic advantages of natural rubber. This research demonstrates a sustainable pathway toward high-performance elastomeric materials, bridging the gap between conventional and advanced solutions in modern engineering applications.
Murugesan, Annarajan, Hingalaje, Abhijeet, Perumal, Mathavan, Pawar, Rohit
Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charger System2026-26-02831/16/2026
This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal conductivity was conducted through SEM. The resulting insights contributed to understanding the structural changes that contributed to the improved thermal performance. Subsequently, the developed thermally conductive mat sheet was evaluated in the context of wireless charger performance. The findings and implications of these evaluations were thoroughly discussed. In summary, this research successfully developed a thermally conductive TPE mat and highlighted its superior performance in terms of wireless charging efficiency compared to the traditional antiskid mat. Thermal and morphological analyses provided deeper insights into the material properties, while the evaluation of the mat's impact on wireless charger performance demonstrated its practical significance.
Naikwadi, Amol Tarachand, Mali, Manoj, Patil, Bhushan, Tata, Srikanth
Material-Optimization in Rib-Stiffened Polymer Structures: A Computational & Analytical Study2026-26-04981/16/2026
The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. The current literature focuses on single ribbed or homogeneous plate behavior. Understanding the behavior in parallel rib arrangement with inter connections – especially when the ribs are spaced close together is yet to be done. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel dual-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending performance. The study attempts to understand the behavior of Polypropylene plates specifically, their bending stiffness, load transfer enhancement of the cross-rib structure through mathematical and computational methods. The study also compares the mechanical performance of single ribbed structure to that of parallel and cross-ribbed plates. The cross ribbed plate structure will help in increasing the packaging space and weight reduction.
Sreejith, M P, Jain, Deepak, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
Influence of the PTFE on the Tribological and Mechanical Properties of a Fiber-Reinforced Polyphthalamide2025-36-022112/18/2025
Materials science and engineering are essential for advancing energy-efficient mechanical systems through lightweight structures and friction reduction. Among engineering polymers, polyphthalamides (PPA) are widely used for their superior thermochemical and mechanical properties. This study investigates the influence of polytetrafluoroethylene (PTFE) on the mechanical and tribological performance of a commercial polymer matrix composite (PMC) reinforced with 30wt% glass fiber. Self-lubricating composites were manufactured by injection molding with PTFE contents ranging from 0-15 wt%. Density was measured using Archimedes’ method. Mechanical properties were measured through ISO 527 tensile testing, while tribological behavior was evaluated using ball-on-flat reciprocating tests under 189N (630 MPa), 2 H frequency, and 10 mm strokes for 60 minutes, employing a 10 mm diameter AISI 52100 steel sphere as counter-body. Friction coefficient (COF) was monitored throughout testing, and wear mechanisms were investigated using white-light interferometry (WLI), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). Wear volumes were obtained from contact profilometry. Results show that PTFE addition reduced mechanical strength decreasing by 7.9%, 8.5% and 14.8% for 2%, 5% and 15% PTFE, respectively. In contrast, tribological performance improved, with COF stabilizing between 0.03-0.08 and wear rate decreasing from 5.6 × 10-4 mm3/N.m (no lubricant) to 1.0 × 10-4 mm3/N.m for 2 and 5% PTFE. At 15% PTFE, wear rate and COP increased to 2.3 × 10-4 mm3/N.m and 0.08, respectively. EDS analysis detected fluorine on the wear surfaces, confirming the formation of PTFE-rich tribolayers. However, excessive PTFE compromises mechanical integrity due to the formation of large reservoirs, leading to increased deformation and wear under high pressure. Thus, optimal performance results from balancing PTFE content and mechanical in robustness.
Hromatka, Matheus, Salvaro, Diego B., Binder, Cristiano, Michelotti, Alvaro C., Berto, Lucas F.
Natural Fibers Applied in the Automotive Industry in Brazil: A Review2025-36-017012/18/2025
There is a growing demand for new materials that meet mechanical and structural performance requirements, with specific properties, especially in the automotive industry. From a context of innovation and global needs to be met, there is the appreciation of composite materials, specifically applied in the automotive sector, since these can be obtained from the combination of two or more different materials, obtaining certain properties from the individual characteristics of its phases, expanding the availability of materials to be used in this sector. In recent years the use of natural fibers in composite materials for automotive applications has gained relevance due to factors such as sustainability, low weight and good mechanical properties. The attempt to combine innovation and environmental preservation make such applications promising, aiming to obtain ecological solutions, considering that natural fibers of vegetable origin such as sisal, jute and flax are biodegradable and renewable, being an environmentally friendly alternative compared to synthetic fibers such as glass and carbon. Sisal fiber, for example, is already used in coatings, interior panels and car sound insulation. Therefore, the present work aims to present a review about the general panorama of the use of natural fibers and composites reinforced by such fibers at national level in the automotive sector. For this, will be cataloged articles, dissertations, course completion work etc. for the interval of 2014 to 2025, which are related to this theme, from university libraries, academic platforms or directly in journals dedicated to engineering among other sources of information, being presented the main thermoplastic and thermofix matrices used, such as polypropylene, polyester and epoxy, in addition, the presentation of natural fibers found in Brazil, such as jute, sisal, coconut and curaua. In addition, attending conferences and symposia in the area can provide updated and relevant information to present the main applications, research and trends on the subject. Thus, research on the use of natural fibers in the automotive industry is growing, reflecting the increased demand for more sustainable solutions.
Dias, Roberto Yuri Costa, Santos Borges, Larissa dos, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor de, Silva de Mendonça, Alian Gomes da, Fujiyama, Roberto Tetsuo
Optimizing the Structural Finite Element Method based Process to Evaluate the Sustainable Human Accidental Sliding Load of Automobile Airvent Knob Design Made with Thermoplastic PC - ABS2025-28-028911/6/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit finite element analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in non-prestressed condition. The research work proposes a FEM based analysis approach to evaluate the mechanical breakage load of airvent knob assembly for accidental sliding load. This process skips the assembly level snap insertion load case along with silicone rubber pad compression which could serve as the prerequisite simulation. This prerequisite simulation is computationally expensive and complex to solve due to polymer plasticity and silicone rubber elastomer hyper-elasticity and moving frictional contacts between parts. If the accidental sliding load case without considering pre-tension on snaps is simulated, the load causing mechanical failure in the FEM based analysis is not correlating with experimental prototype samples breakage force values. The strain at break for composite, polycarbonate (PC) with acrylonitrile-butadiene-styrene (ABS) material used for knobs, is 100%. By considering the lower strain criteria of 5%, the analysis results and experimental testing results in terms of load causing mechanical breakage and breakage zones are co-related. To validate the established breakage strain criteria of 5%, another airvent knob design with same material of knob is considered for study. A good correlation is established between FEM approach and experimental testing. It is concluded from the outcomes of the FEM based analysis that the 5% strain as breakage criteria set for capturing knob strength for accidental sliding load case is efficient. The same process set can be utilized for developing more airvent knobs.
Shah, Viren, Miraje, Jitendra
3D Printed Injection Molding Tool: An Unique Approach for New Product Development2025-28-032111/6/2025
Automotive industry frequently uses 3D printed plastic proto parts during new product development phases as it bypasses the high tooling investment & development time at early part development stage. However, for some application, 3D printing technique & its limited material options are not fulfilling the required material properties in the part, resulting poor performance during product testing which may mislead the design engineer during validation process. To overcome this, we introduce a novel approach in constructing injection molding tool by 3D printing the core and cavity using Stereolithography (SLA). This enables production of parts with application-recommended material grades, facilitating traditional validation and increasing stakeholder confidence. This paper compares part quality from 3D printed molds against conventional metallic molds for a shifter gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life analysis using PP Glass Filled 30% (PPGF30) and Nylon 66 Glass Filled 30% (Nylon 66GF30) yielded approximately 100 and 25 parts, respectively. We also discussed the challenges encountered during the mold 3D printing and injection molding process. This innovative technique offers broad applicability across plastic part manufacturing industries.
Gandhi, Sorna Rajendran, Gunduboina, Chaitanya
Temperature Effect on Fatigue Performance of Thermoset and Thermoplastic Composites2025-32-000611/3/2025
The growing demand for lightweight, durable, and high-performance materials in industries such as aerospace, automotive, and energy has driven the development and evaluation of thermoset and thermoplastic composites. Within this framework the static and fatigue mechanical behavior of one thermoset material and two thermoplastic composites are investigated in the (-30° +120°C) temperature range, to simulate extreme environmental conditions. The results from the tensile tests show the different mechanical behavior of the investigated materials, while the cyclic test results highlight the significant impact of temperature on structural properties, offering useful insights for their application in temperature-sensitive environments. This research is partially funded by the Italian Ministry of Enterprises and Made in Italy (MIMIT) within the project ”New Generation of Modular Intelligent Oleo-dynamic Pumps with Axial Flux Electric Motors,” submitted under the ”Accordi per l’Innovazione” call (DM 31/12/2021, DD 10/10/2022, automotive sector).
Chiocca, Andrea, Sgamma, Michele, Franceschini, Alessandro, Vestri, Alessio, mancini, Simone, Bucchi, Francesco, Frendo, Francesco, Squarcini, Raffaele
How AI Can Find the Next Groundbreaking PolymerTBMG-5412511/1/2025
Nylon, Teflon, Kevlar. These are just a few familiar polymers — large-molecule chemical compounds — that have changed the world. From Teflon-coated frying pans to 3D printing, polymers are vital to creating the systems that make the world function better.
Film Cast PTFE Liner and Tubing: An Inside Look at Quality from a Manufacturing PerspectiveTBMG-532846/1/2025
Blade Stiffened Carbon/Epoxy Panels with Longitudinally Tapered Acoustic Black Holes for Vibration ReductionF-0081-2025-02765/20/2025
Carbon/epoxy stiffened panels are being increasingly used in transport rotorcraft. The reduced mass density and high stiffness of carbon/epoxy composites can lead to higher levels of vibration relative to comparable metallic structures, which themselves can have vibrations and interior noise high enough to damage the hearing of crew and passengers. The current investigation explores a method to reduce the vibration of carbon/epoxy stiffened panels by introducing thickness tapers known as acoustic black holes (ABHs). The ABH feature is integrated into either the stiffeners or plate of a representative stiffened panel configuration. A finite element (FE) parametric study was used to guide designs that reduce the vibration of the panel without compromising the compressive buckling capability or mass of the panel. FE studies showed that a 30 ply to 12 ply thickness taper longitudinally oriented in the blade stiffener can reduce vibrations and increase compressive buckling capability. Carbon/epoxy panels were manufactured using a low-cost out-of-autoclave material with simple molding. Experimental testing concluded that integrating the ABH into the stiffeners longitudinally helped to reduce the broadband vibration by 5 dB and increase the buckling load (+4.3%) and collapse load (+16.5%) without increasing the mass greatly compared to a traditional baseline design.
Brown, Avery, Patel, Bhavya, Robertson, Noah, Bakis, Charles, Smith, Edward, Beck, Ben, Shepherd, Micah, Vlajic, Nicholas
Lightweight Low-Cost Multifunctional Thermoplastic Composite AirframeF-0081-2025-01625/20/2025
With performance advances proposed for the Future Vertical Lift suite of aircraft and advancements in the electronic battlefield, it is imperative that advanced materials and concepts be included in the vehicle designs to meet the aggressive weight reduction objectives, structural requirements, and operational environment capabilities. Integrating electromagnetic (EM) shielding during the design process offers an opportunity to make progress towards the performance goals. To this end, efforts must be made to minimize the impact of this shielding to platform weight and structural performance. This article presents work to develop a hybrid multifunctional composite material technology that incorporates copper mesh into a carbon fiber and thermoplastic matrix structural composite material to achieve required levels of EM shielding and high levels of structural efficiency while reducing the overall weight of the system. This article focuses on the design of a representative helicopter tailcone as means of illustrating expected improvements in weight and manufacturing cost. Baselines that include structure fabricated from aluminum and thermoset composite are established and predicted improvements quantified.
Haynes, Robert, Luzetsky, Harry, Phifer, Ellen
Material Adapted Method for the Repair of Curved Thermoplastic Composite Structures by Induction Welding of Patches2025-01-01655/2/2025
Thermoplastic fiber-reinforced polymer composites (TPC) are gaining relevance in aviation due to their high specific strength, stiffness, potential recyclability and the ability to be repaired thanks to their meltability. To maximize their potential, efficient repair methods are needed to maintain aircraft safety and structural integrity. This article introduces a novel repair technique for damaged TPC structures, involving the joining of a repair patch with induction welding using a susceptor material. The susceptor consists of a material with high electrical conductivity and magnetic permeability and therefore reacts stronger to the electromagnetic field than the composite, even if the composite is carbon fiber based. I. e. the thermal energy is specifically concentrated in the repair area. In this study, the susceptor was placed on the patch and also in the welding zone. The repair process begins by identifying and preparing the damaged area, followed by precise scarfing. Care is taken to ensure that the surrounding material remains intact and that an exact stepped structure is created, which enables an optimal bonding with the patch to be used. The customized patch, which fits perfectly in terms of shape and material to the area to be augmented, is then inserted into the structure. Induction heating melts the thermoplastic matrix to join the patch with the structure using a flexible induction mat. The repair process is monitored using thermocouples to ensure even heat distribution, while pressure is maintained through a vacuum bag. The vacuum bag ensures a uniform pressure distribution even on complex curved structures. This adaptable repair method can handle individual damages. It was tested on flat carbon fiber-reinforced polyphenylene sulfide (CF-PPS) structures, showing repairs with nearly 70 % of the original performance for copper mesh susceptors. Optical tests of the specimens confirmed a bonding zone with minimal defects. Overall, this method offers a material-compatible solution for TPC repair in future aviation, advancing aerospace maintenance and offering significant potential for future industry use.
Geiger, Markus, Glaap, Anton, Schiebel, Patrick, May, David
Finite Element Simulation and Experimental Study of the in-Mold Graining Process2025-01-83304/1/2025
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum forming process. Numerical simulation of the vacuum forming process of TPO material is conducted using Polyflow software, investigating issues such as the establishment of the solid model, meshing principles, and the selection of simulation models. Taking an inner door panel of vehicle as an example, simulations were performed and compared with the actual product's thickness for verification. The results indicate that the error between the simulated and the measured thickness is less than 5%, which can provide a reference for actual manufacturing.
Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu
A Systematic Review about Heat Shrink Sleeves Using Nanomaterials for the Automotive Industry2025-01-83294/1/2025
Heat shrink polymer is a type of material used in many industries’ segments due to their ability to contract and fit snugly around objects when heat is applied. These products are commonly commercialized in tube format (e.g.: sleeves), made from polyolefin or fluoropolymers, which have the property of shrinking when heated. Nanomaterials present many applications, and their usage is a remarkable tool aiming to improve many properties of materials. Then, many improvements including increase of performance and price reduction may be achieved due to its unique properties when nanomaterials are used into heat shrink polymer sleeves. This work presents a systematic review about the state of the art on heat-shrinkable materials for the automotive industry. As a methodology, articles from the last 10 years on the subject were selected. The keywords “heat shrink” AND “nanomaterial” AND “tubes OR sleeves” were used in three different databases, being “Scopus”, “Web of Science” and “MDPI”. After using the keywords, articles only in English were selected, excluding conference and review articles. As a result, 513 articles were obtained. Those that use polyethylene as a matrix for the heat shrink were selected, being the main scope. As a result, 53 articles were obtained, using exclusion and inclusion criteria. The main nanomaterial used in the studies was montmorillonite with 27 articles, followed by other nanosilicates, such as nanoquartz among others. Graphene and its derivatives also appeared in the research, with 6 articles. Finally, new trends were found for the use of nanofillers and other matrices can also be explored in the future, such as polypropylene.
Kerche, Eduardo F., Polkowski, Rodrigo, Horiuchi, Lucas, Goncalves, Everaldo
Evaluation of Additively Manufactured Thermoplastic Composite Magnetic Field Shielding for Stepper Motors2025-01-82014/1/2025
As stepper motors become more and more widely used in engineering systems (vehicles, 3-D printers, manufacturing tools, and similar), the effects of their induced magnetic fields present a concern during the packing and orientation of components within the system. For applications requiring security, this is also a concern as the background electromagnetic radiation (EMF) can be captured at a distance and used to reproduce the motion of the motor during operation. One proposed alternative is to use customized non-magnetic plastic shields created using additive manufacturing. Some small studies have been completed which show some effectiveness of this approach but these studies have been small-scale and difficult to reproduce. To seek a more rigorous answer to this question and collect reproducible data, the present study used full factorial design of experiments with several replications. Three materials were used: Polylactide (PLA), PLA with 25% (weight) copper powder, and PLA with 15% chopped carbon fibers. The factors of interest were infill pattern (gyroid, octet, and concentric) and shield wall thickness (10mm, 20mm, and 30mm), while the response used was strength of magnetic field at two distances (100mm and 200mm) from the motor at various angles. A total of 27 different shield designs were manufactured and tested, with a total of 1176 tests being completed. The results showed some effect, both in shielding and in increasing the magnitude of the EMF, but the effect was significantly smaller than what was shown in some previous screening studies suggesting that some previous studies had a lot of noise in the data. The replications showed excellent consistency, showing that the results are reliable. It was concluded that additively manufactured stepper motor shielding can be used effectively in some cases but is likely not the best shielding option for many scenarios in vehicles and similar applications.
Hu, Henry, Patterson, Albert E., Karim, Muhammad Faeyz, Porter, Logan, Kolluru, Pavan V.
Brittle or Ductile? Effects of Print Orientation and Raster Angle on Polylactic Acid (PLA) Fused Filament Fabrication (FFF) Tensile Samples2025-01-83354/1/2025
The automotive industry leverages Fused Filament Fabrication (FFF) -based Additive Manufacturing (AM) to reduce lead time and costs for prototypes, rapid tooling, and low-volume customized designs. This paper examines the impact of print orientation and raster angle on the tensile properties of Polylactic Acid (PLA), selected for its ease of use and accessibility. Dog bone samples were designed to the ASTM D638 tensile testing standard and printed solid with a 0.2 mm layer height, two outer walls, and varying raster-fill angles, with layers alternating by 90°. Testing was conducted on the MTS Criterion Model 43, 50 kN system. Varying print orientation along the X and Y axes (double angle builds) produced a Young's modulus (YM) range of 0.7519, reflecting a 34.42% increase between the witnessed minimum and maximum values. These builds exhibited more brittle behavior than most single angle builds, except for X10 Y10 Z0 at a 45° raster (the lowest recorded YM) and X0 Y15 Z0 at a 30° raster (the highest recorded YM). The same build orientation (X0 Y15 Z0) with varying raster angles between 0°-90° resulted in a yield stress range between 2.53 and 3.31 kN/mm2. These findings show that strategic build parameter configuration enables PLA to exhibit both flexible and rigid characteristics. Therefore, when creating AM solutions, Design for Additive Manufacturing (DfAM) and material selection are important, but slicing parameters also play a crucial role in determining a part's final mechanical properties. These findings lay the groundwork for applying this experiment methodology to other thermoplastics commonly used in the automotive industry, such as ABS and Nylons. This research aims to provide detailed experimental data, highlighting extreme values and uncertainties in the tensile strength of FFF samples. Understanding how build orientation influences part strength can help engineers optimize performance and predict failure modes.
Strelkova, Dora, Urbanic, Ruth Jill
Thermal Insulation Tiles and Sheets Based on Integration of Recycled Plastic Waste Fibres and Epoxy Resin2025-01-83254/1/2025
Plastic waste, in the past few years, has risen to be one of the most concerning and endangering pollutants to environment and life, making its effective management and reduction a major domain of focus among researchers and industrialists. This comparative study is an attempt to utilize recycled Polyethylene Terephthalate (rPET) fibres combined with Epoxy Resin in various combinations, to provide effective and low-cost insulation in moderate to low requirements. The above-mentioned components serve as viable insulators. Moisture resistance of both materials and temperature resistance of Epoxy resins ranging from 120°C to 150°C (depending upon the grade of Epoxy used) indicate a good stability in harsh external operating environment. While Epoxy resins are not inherently flame retardants, additives are introduced for this purpose in order to render the composite safer to use. Owing to the excellent adhesive properties of the Epoxy resin, the rPET fibres are allowed to bond together firmly and also exhibit good overall strength of the composite and also making sure that the composite will not delaminate or weaken over time. Controlled environmental experiments and mathematical modelling of the real-life conditions have been performed. As a part of this study, multiple configurations of the mentioned composite have been tested experimentally and simulatively with varying overall thickness ranging from 3mm to 15mm. Results show temperature difference of about 12°C, indicating that the composites developed can be used as effective thermal insulators.
Purihella, Sri Sai Krishna, Pali, Harveer Singh, Kumar, Piyush, Sharma, Ved Prakash
Effects of Aging on PVC-Based Instrument Panel Skin for Passenger Airbag Deployment Analysis2025-01-83214/1/2025
Plasticized polyvinyl chloride (PVC) has many applications in automotive industry including electrical harnesses, door handles, seat and head rest covers, and instrument panel (IP) and other interior trim. In IP applications, the PVC skin plays a critical role in passenger airbag deployment (PAB) by tearing along the scored edge of the PAB door and allowing the door to open and the airbag to inflate to protect the occupant. As part of the IP, the PVC skin may be exposed to elevated temperatures and ultraviolet (UV) radiation during the years of the vehicle life cycle which can affect the PVC material properties over time and potentially influence the kinematics of the airbag deployment. Chemical and thermal aging of plasticized PVC materials have been studied in the past, yet no information is found on how the aging affects mechanical properties at high rates of loading typical for airbag deployment events. This paper compares mechanical properties of the virgin PVC-based IP skin material with the same material after it has been exposed to 110°C for 400h. Both, virgin and aged materials, were tested at three temperatures, viz. -30°C, 23°C and 85°C and at four strain rates ranging from 0.01/s to 100/s. Finally, effects of the aged material on the PAB deployment simulation are discussed.
G, Karthigan, Savic, Vesna, Ravichandran, Gowrishankar
Capillary Transport Analysis in Macro-Homogeneous Diffusion Media of PEM Fuel Cells2025-01-85464/1/2025
The interplay of electrochemistry, two-phase flow, and heat transfer generates complex transport phenomena within the porous materials of fuel cells that are not yet fully understood. This lack of comprehensive understanding complicates the modeling of liquid water transport, which is critical because the hydration of the polymer electrolyte membrane significantly impacts the cell performance. The liquid water transport mechanisms in porous media can be explained by capillary force, hydraulic permeation and gravity effects, as well as water condensation and evaporation. In general, the liquid water transport is mainly driven by the capillary force, while body forces, such as gravity, do not significantly affect its momentum. Due to limited experimental data on capillary pressure and saturation in gas diffusion media, the Leverett approach has been widely used for modeling liquid water transport in PEMFCs. The Leverett approach is a polynomial fitting of capillary pressure data for water imbibition in unconsolidated sand packs. Due to its nature, this approach may not accurately predict capillary pressure in gas diffusion media. Fuel cell GDM materials, naturally hydrophilic, are typically coated with a nonwetting polymer like polytetrafluoroethylene to create hydrophobic surfaces and pores. The resulting nature of GDM materials, with intermediate wettability due to the coexistence of hydrophilic and hydrophobic pore spaces, complicates transport phenomena. Consequently, the applicability of the traditional Leverett approach is questionable. This work focuses on capillary transport within PEMFCs, highlighting key experimental and modeling approaches for predicting the capillary pressure-saturation relationship. Starting from the Leverett function, improved models have been proposed and are here implemented in a 3D-CFD model. This research provides an overview of key experimental and theoretical developments in understanding capillarity in PEMFCs. Furthermore, it implements selected capillary pressure correlations in a 3D-CFD model to evaluate their performance in simulating water transport within the porous media, providing guidelines for their use in large-scale models.
Marra, Carmine, Croci, Federico, Fontanesi, Stefano, Berni, Fabio, D'Adamo, Alessandro
Lighter, recyclable body seal wins SAA award25AUTP03_083/1/2025
A lighter, colorable and fully recyclable thermoplastic body seal from Cooper Standard won the annual Innovations in Lightweighting Award given by the Society for Automotive Analysts. At the society's December meeting, Jay Murdock, senior product development engineer for Cooper Standard, accepted the award and said its FlexiCore product was designed with an eye on strong trends in what OEMs want from suppliers: sustainability, carbon neutrality, lightweighting and recyclability.
Clonts, Chris
Characterization of Mechanical, Thermal, and Chemical Properties of Natural Fiber Composites: A Case Study of Bamboo Leaves and Coconut Leaves2025-28-01122/7/2025
The research project focused on investigating the mechanical, thermal, and chemical properties of composite plates made from bamboo leaves and coconut leaves reinforced with epoxy resin that has received limited attention in previous studies. The bamboo and coconut leaves underwent alkaline treatment, were thoroughly washed with distilled water, and dried in sunlight for 24 hours. For the fabrication of three composite plates, Hand lay up method was employed according to the American Society for Testing and Materials (ASTM) standards. The compositions of the composite plates were varied as first Composition has 25 wt% bamboo leaves, 25 wt% coconut leaves and 50 wt% resin, the Second Composition has 30 wt% bamboo leaves, 30 wt% coconut leaves, and 40 wt% resin and the third composition has 35 wt% bamboo leaves, 35 wt% coconut leaves, and 30 wt% resin. Tensile test, shear and flexural tests helped determine the tensile strength, shear strength, and flexural strength of the composite materials. Additionally, Thermo- gravimetric analysis (TGA) was performed according to ASTM E- 1131 to assess the degradation temperature of the composite plates. Additionally, Fourier-transform infrared spectroscopy (FTIR) tests were also conducted to identify the functional groups of the organic materials present with in the composite plates. The outcomes of this research are anticipated to contribute to a more sustainable utilization of waste bamboo and coconut leaves.
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, S, Edwin Roshan
Study of Mechanical, Barrier and Tribological Behaviour of Jute & Glass Fiber Epoxy Hybrid Polymer2025-28-00312/7/2025
The incorporation of natural available material into synthetic materials to form a fiber within a single polymer matrix has been ignited since environment concerns become crucial nowadays. Composite materials embedded with two or more types of fibers makes a composite as hybrid. The study of hybridization of natural and synthetic fibers brings out superior mechanical and tribological properties. In our present studies, fabrication of jute & glass fiber reinforced epoxy-based polymer hybrid composites were carried out using resin infusion technique. For comparing the various properties, the composite made of pure jute fiber i.e 100% jute, pure glass fiber i.e 100% glass, the hybrid composite containing 75% jute and 25% glass fiber, 50% jute and 50% glass fiber, and 25% jute and 75% glass fiber were made and its functional behaviors were studied. The results revealed the hybrid composite containing 25% jute and 75% glass fiber possessed maximum tensile strength of 292±5.8 MPa, flexural strength of 188.3±3.7 MPa, impact strength of 130±2.6 kJ/m2, storage modulus of 17050MPa, loss modulus of 2883MPa, and minimum moisture absorption and wear loss. As compared with the obtained values of composite containing pure jute fiber, tensile strength was increased by 346%, flexural strength increased by 278%, impact strength increased by 227%, hardness increased by 184%, storage modulus increased by 431%, loss modulus increased by 454%, moisture absorption decreased by 88% and wear loss decreased by 100% . Thus prepared hybrid composites, could be employed in different automobile components such as panels, fenders, engine components, brake pad materials, bonnets and heat shields.
J, Chandradass, T, Thirugnanasambandham, M, Amutha Surabi, P, Baskara Sethupathi, Rajendran, R, Murugadoss, Palanivendhan
Investigating Mechanical Properties of Jute Fiber and Alumina-Reinforced Epoxy Composites: Application of Taguchi and Grey Analysis for Automotive Components2025-28-01132/7/2025
Natural fiber composites (NFC’s) have considerable promise for a wide range of technological applications due to their exceptional features, which include notable weight reduction, high strength, and affordability. The aforementioned materials are also biodegradable and sustainable, which makes them appealing for use in sustainable engineering methods. This research focuses on evaluating the mechanical features of jute fiber and Al₂O₃ particle fortified polymer composites, exploring their potential for advanced engineering uses. The Taguchi technique is used with a L9 orthogonal array, integrating three-level, three-parameter approach, to systematically examine potential combinations of process variables in the manufacturing of these polymer composites. The primary goal is to optimize the mechanical attributes of the composites, which include tensile modulus, tensile stress, and weight percentage increase. Detailed investigations are conducted to interpret the effects of these process factors on the performance metrics. The research employs ANOVA and regression evaluation to assess the pertinence of process factors on the individual output variables. Furthermore, interaction assessment is carried out to discover the implications of the impact of interactions among the process factors on the intended performance measures. To examine the multi-performance index, Grey analysis is used to establish the Grey Relational Coefficient (GRC) values, which provide a comprehensive performance assessment. The resulting composite materials demonstrate considerable potential for application in interior automotive components, such as dashboards and luggage compartments, due to their enhanced mechanical properties and environmental benefits.
Somsole, Lakshmi Narayana, Natarajan, Manikandan, Pasupuleti, Thejasree, Katta, Lakshmi Narasimhamu, Vivekananda, Soma
Optimization of Fusion Deposition Modeling Parameters for PLA Material for Automobile Interior Using Taguchi Based TOPSIS Approach2025-28-01312/7/2025
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly nature, affordability, and ease of processing. This study aims to optimize the parameters of Fused Deposition Modeling (FDM) for PLA material using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach. The researchers performed experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including dimensional accuracy, surface finish, and mechanical properties. The methodology of design of experiments (DOE) enabled a systematic exploration of parameters. The TOPSIS approach, a technique for making decisions based on multiple criteria, was used to analyze the experimental data and determine the best parameter settings. TOPSIS provides a comprehensive method for optimizing parameters in FDM by taking into account both the closeness to the ideal solution and the distance from the negative ideal solution. The results demonstrated the efficacy of the TOPSIS method in pinpointing the most advantageous parameter combinations for improving the printing quality and efficiency of PLA components. The optimization framework that has been developed offers valuable insights into the optimization and control of processes, thereby facilitating the wider implementation of FDM technology across different industries. This study enhances the comprehension of Fused Deposition Modeling (FDM) for Polylactic Acid (PLA) material and provides useful techniques for optimizing FDM parameters. Manufacturers can improve printing productivity, quality, and sustainability by utilizing the TOPSIS approach. This, in turn, will help promote the wider use of AM technology in various applications.
Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Katta, Lakshmi Narasimhamu, Silambarasan, R
Development of AI Prediction Tool for Fused Deposition Modeling of ABS Material for Automobile Applications2025-28-01272/7/2025
Fused Deposition Modeling (FDM), a form of Additive Manufacturing (AM), has emerged as a groundbreaking technology for the production of complex shapes from a variety of materials. Acrylonitrile Butadiene Styrene (ABS) is an opaque thermoplastic that is frequently employed in additive manufacturing (AM) due to its affordability and user-friendliness. The purpose of this investigation is to enhance the FDM parameters for ABS material and develop predictive models that anticipate printing performance by employing the Adaptive Neuro-Fuzzy Inference System (ANFIS). Through experimental trials, an investigation was conducted to evaluate the influence of critical FDM parameters, including layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including mechanical properties, surface polish, and dimensional accuracy. The utilization of design of experiments (DOE) methodology facilitated a systematic examination of parameters. A predictive model was developed to forecast printing performance by utilizing input parameters and ANFIS. The ANFIS predictive models' ability to accurately predict the printing performance of ABS material was demonstrated by the results. Moreover, the models provide vital insights into the most effective parameter configurations for ensuring high-quality parts and maximizing printing efficiency. This investigation improves the understanding of Fused Deposition Modeling (FDM) for Acrylonitrile Butadiene Styrene (ABS) material and offers a practical instrument for manufacturing process optimization. By employing ANFIS predictive models, manufacturers can enhance the quality and productivity of printing. This will facilitate the expansion of the application of FDM technology in various sectors, including healthcare, manufacturing, and prototyping.
Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R
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