4LM20 - Polymer Processing

Polymers have very attractive properties for use in all kinds of products. For example, they have a low density but also good mechanical, optical and, recently, electrical properties (solar cells, polymer electronics). Designers have great freedom in shaping their products. Furthermore, products can be manufactured in a fully automated process at relatively low temperatures in an energy efficient way. Since polymers consist of long-chain molecules they are very stretchable leading to unique products, such as, fibers made by spinning having a strength ten times larger than steel or foils having a thickness of 1 micron, a width of 6 meters and infinitely long. 

The obtained properties are directly related to the process the polymer has undergone. Due to the long-chain structure some disadvantages also exist, such as a high viscosity demanding special manufacturing processes and (frozen in) chain orientation leading to anisotropic properties and unpredictable long-time dimensional stability of high-precision injection moulded parts. In the end, the final properties of the polymeric product are determined by the full thermo-mechanical history during forming.

This course discusses the major concepts of polymer processing. Conventional processes like injection moulding, blow moulding, mixing and extrusion are covered, but also the basics of newer methods like electro spinning, roll-to-roll printing and 3d printing of polymers are taught. Special attention is given to instabilities in processing, distributive mixing and flow-induced crystallisation.

• fundamental insight in polymer processing process like injection moulding, blow moulding, mixing and extrusion
• the student can describe the variety of flow phenomena that can occur in these processes 
• the student understands the concepts of distributive and dispersive mixing
• the student can describe the working principles of static and dynamic mixers
• the student has technical and theoretical knowledge about flow-induced crystallisation
• the student can describe the origin of the onset of different elastic instabilities
• the student can an overview of the different 3d printing principles