The activities performed during the project focused on hybrid polymer processing technologies, integrating material science with sophisticated mathematical modeling:
Advanced Hybrid Processing and Mathematical Modeling
• Interfacial Bonding Strength Modeling: Researchers developed an advanced mathematical model utilizing reptation theory and 3D temperature distribution data from Finite Element Method (FEM) simulations to predict bonding strength between overmolded polymer components.
• Synthesis of Covalent Adaptable Networks: The project successfully synthesized a new generation of polymers known as Covalent Adaptable Networks (CANs) or vitrimers.
• The "Reversible Glue" Concept: A major breakthrough was the development of CANs that act as reversible adhesives, enabling the welding of traditionally incompatible polymers and facilitating triggered debonding for high-quality recycling.
• Self-Healing and Functional Fillers: Materials were modified with functional fillers, including carbon nanotubes (CNTs) for thermal conductivity and magnetite powder for induction responsiveness.
• Hybrid Manufacturing Validation: The research evaluated the bond integrity between injection-molded parts and substrates produced via Fused Filament Fabrication (FFF) and Selective Laser Sintering (SLS).
• Functional Demonstrator: The research culminated in a physical prototype consisting of an injection-molded vitrimer PP plate overprinted with an ABS-vitrimer composite rib. The demonstrator proved that hybrid parts can be made repairable and reconfigurable, achieving localized heating and triggered debonding through infrared (IR) activation.
Technical Capacity Building and Knowledge Transfer
• Specialized Technical Workshops: A series of 18 workshops were implemented, providing researchers with hands-on expertise in sensor-based injection molding, Industry 4.0 digitization, and advanced compounding technologies.
• Technical Summer Schools: Three summer schools focused on composite technologies, advanced injection molding, and compounding, facilitating deep technical interaction between early-stage researchers and international experts.
• Advanced Material Characterization: Through staff exchanges, researchers gained specialized skills in advanced rheological measurements (using Anton Paar MCR 702), viscosity modeling, and material data determination for high-fidelity simulations.
