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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

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Published on: August 4, 2018

Polypropylene injection molded part with novel macroscopic bamboo-like bionic structure.

Run Su¹, Zeqi Zhang, Xiang Gao

¹Department of Polymer Science and Materials, State Key Laboratory of Polymer Materials Engineering, Sichuan University, Chengdu, 610065, PR China.

The Journal of Physical Chemistry. B

|August 6, 2010

Summary

Researchers created a bamboo-like structure in polypropylene using melt manipulation and a beta-nucleator. This design significantly enhances both the material's toughness and strength through controlled shear intensity during molding.

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Area of Science:

Materials Science
Polymer Science
Mechanical Engineering

Background:

Isotactic polypropylene (iPP) is a widely used thermoplastic.
Improving the mechanical properties of iPP, such as toughness and strength, is crucial for broader applications.
Traditional methods often involve complex additives or processing conditions.

Purpose of the Study:

To fabricate a macroscopic bamboo-like bionic structure in injection-molded iPP.
To investigate the influence of shear intensity on the resulting hierarchical structure, polymorphism, and crystalline morphology.
To demonstrate an effective strategy for achieving enhanced comprehensive mechanical properties in iPP.

Main Methods:

Fabrication of a bamboo-like structure using "melt manipulation" and a beta-nucleator in isotactic polypropylene.
Utilizing injection molding to control shear intensity during the process.
Analysis of structural hierarchies, beta-phase content, crystalline morphology, and mechanical properties (toughness and strength).

Main Results:

A distinct bamboo-like structure was successfully created, featuring a strengthened shell zone and a toughened core.
Higher shear intensity led to increased orientation in the shell and a dominant beta-modification in the core.
Both toughness and strength of the polypropylene were significantly improved with increasing shear intensity.

Conclusions:

Macroscopic structural design during practical molding processes offers an alternative route to enhance iPP mechanics.
The combination of "melt manipulation" and beta-nucleation provides a pathway to tailor iPP's microstructure for superior performance.
The developed bamboo-like structure demonstrates a promising approach for achieving excellent comprehensive mechanical properties in polypropylene.