Jonathan E. Seppala

Infrared thermography of welding zones produced by polymer extrusion additive manufacturing

In common thermoplastic additive manufacturing (AM) processes, a solid polymer filament is melted, extruded though a rastering nozzle, welded onto neighboring layers and solidified. The temperature of the polymer at each of these stages is the key parameter governing these non-equilibrium processes, but due to its strong spatial and temporal variations, it is difficult to measure accurately. Here we utilize infrared (IR) imaging - in conjunction with necessary reflection corrections and calibration procedures - to measure these temperature profiles of a model polymer during 3D printing. From the temperature profiles of the printed layer (road) and sublayers, the temporal profile of the crucially important weld temperatures can be obtained. Under typical printing conditions, the weld temperature decreases at a rate of approximately 100 °C/s and remains above the glass transition temperature for approximately 1 s. These measurement methods are a first step in the development of strategies to control and model the printing processes and in the ability to develop models that correlate critical part strength with material and processing parameters.

Rapid fabrication of poly(DL-lactide) nanofiber scaffolds with tunable degradation for tissue engineering applications by air-brushing

Polymer nanofiber based materials have been widely investigated for use as tissue engineering scaffolds. While promising, these materials are typically fabricated through techniques that require significant time or cost. Here we report a rapid and cost effective air-brushing method for fabricating nanofiber scaffolds using a simple handheld apparatus, compressed air, and a polymer solution. Air-brushing also facilities control over the scaffold degradation rate without adversely impacting architecture. This was accomplished through a one step blending process of high (M w  ≈  100 000 g mol(-1)) and low (M w  ≈  25 000 g mol(-1)) molecular weight poly(DL-lactide) (PDLLA) polymers at various ratios (100:0, 70:30 and 50:50). Through this approach, we were able to control fiber scaffold degradation rate while maintaining similar fiber morphology, scaffold porosity, and bulk mechanical properties across all of the tested compositions. The impact of altered degradation rates was biologically evaluated in human bone marrow stromal cell (hBMSC) cultures for up to 16 days and demonstrated degradation rate dependence of both total DNA concentration and gene regulation.

A composition-controlled cross-linking resin network through rapid visible-light photo-copolymerization

An assembly that delivers well-defined functional materials, clinically practical procedures to make these materials in situ, and appropriate analytical tools for chemical structure and kinetic studies is desirable, though currently unavailable. Herein, we introduce a system that addresses this need through the development and characterization of a cross-linking resin network, which is achieved through rapid, visible-light induced polymerization in a solvent-free environment. This resin network is the result of co-polymerization of a distyrenyl-monomer with a dimethacryl-monomer. Ninety percent of vinyl conversion is achieved in seconds. In addition, an azeotropic composition is identified and confirmed through static end-point evaluation, sol–gel experiment, kinetic study, and mathematical modeling of data acquired via FTIR, real-time Raman and 1H NMR spectroscopies. These results yield opportunities for the design and development of new functional materials to be used in various applications.

Effect of fiber gripping method on the single fiber tensile test: II. Comparison of fiber gripping materials and loading rates

Single poly(p-phenylene terephthalamide) (PPTA) fiber tensile tests were carried out under quasi-static and high strain rate loading conditions using poly(methyl methacrylate) and rubber grips to investigate effects of grip materials and loading rates on fiber tensile properties. Differences in ultimate tensile strengths, failure strains, and moduli of PPTA fibers obtained by two different grip materials were insignificant. On the other hand, the fiber tensile properties showed significantly rate-dependent behaviors, which were graphically confirmed by kernel density plots as a non-parametric statistical analysis. Strength models considering three aspects (stochastic, fracture mechanics, and polymer chain domain behaviors) were also shown to link the loading rate effect in relation to fracture mechanisms.

Characterization of clay composite ballistic witness materials

Mechanical and thermal properties of Roma Plastilina Clay #1 (RP1) were studied through small-amplitude oscillatory shear (SAOS), large-amplitude oscillatory shear (LAOS), and differential scanning calorimetry (DSC), supplemented with thermogravimetric analysis, X-ray diffraction, and X-ray florescence. Rheological characterizations of RP1 through SAOS indicate that the clay composite softens as it is worked and slowly stiffens as it rests. Upon heating, the clay composite softens, prior work history is erased, and the composite undergoes a melting transition, although melted clay is significantly stiffer when returned to the usage temperature. Continuing mechanical characterizations into the LAOS or nonlinear region, RP1 transitions from a transient network to a viscous shear-thinning material as the temperature is increased. Using the MITlaos framework, RP1 exhibits intra-cycle strain stiffening and intra-cycle shear thinning at all temperatures.