Pierre-Etienne Bourban

An Impregnation Model for the Consolidation of Thermoplastic Composites Made from Commingled Yarns

A model for the consolidation of thermoplastic composites based on commingled yarns was developed. The evolution of composite void content during consolidation was related to the processing parameters and the material properties. Additionally, the analysis relied on experimental investigation of the yarn structure, taking into account a distribution in dry fiber bundle sizes. Residual porosity was considered to result from pore closing at a given stage during fiber bundle impregnation. The accuracy of the model was assessed by conducting consolidation experiments using a unidirectional commingled yarn fabric made of polyamide 12 resin and carbon fibers. Excellent correlation was found between predicted and experimental void contents. The model aided prediction of suitable processing conditions and identification of the main physical and geometrical parameters influencing the consolidation rate.

Dynamic properties of sandwich structures with integrated shear-thickening fluids

The integration of shear-thickening fluids (STFs) into composite structures has been investigated with the aim of tuning part stiffness and damping capacity under dynamic deformation. Results from oscillatory rheological measurements for a STF based on concentrated fused silica in polypropylene glycol were correlated with results from vibrating beam tests on model sandwich structures containing layers of the same STF sandwiched between polyvinyl chloride (PVC) beams. Above a critical amplitude, the relative motion of the PVC beams provoked shear thickening of the silica suspensions, and the vibration and damping properties were significantly modified. These changes were related to the rheological response of the STF through analytical calculations of strains in the STF layers, an approach that was verified experimentally by replacing the STF with a slow-curing epoxy resin. The potential for integrating STFs into structures exposed to dynamic flexural deformation, with the aim of controlling their vibrational response, has thus been demonstrated.

Human fetal bone cells associated with ceramic reinforced PLA scaffolds for tissue engineering

Fetal bone cells were shown to have an interesting potential for therapeutic use in bone tissue engineering due to their rapid growth rate and their ability to differentiate into mature osteoblasts in vitro. We describe hereafter their capability to promote bone repair in vivo when combined with porous scaffolds based on poly(l-lactic acid) (PLA) obtained by supercritical gas foaming and reinforced with 5 wt.% beta-tricalcium phosphate (TCP). Bone regeneration was assessed by radiography and histology after implantation of PLA/TCP scaffolds alone, seeded with primary fetal bone cells, or coated with demineralized bone matrix. Craniotomy critical size defects and drill defects in the femoral condyle in rats were employed. In the cranial defects, polymer degradation and cortical bone regeneration were studied up to 12 months postoperatively. Complete bone ingrowth was observed after implantation of PLA/TCP constructs seeded with human fetal bone cells. Further tests were conducted in the trabecular neighborhood of femoral condyles, where scaffolds seeded with fetal bone cells also promoted bone repair. We present here a promising approach for bone tissue engineering using human primary fetal bone cells in combination with porous PLA/TCP structures. Fetal bone cells could be selected regarding osteogenic and immune-related properties, along with their rapid growth, ease of cell banking and associated safety.

Biocomposite Hydrogels with Carboxymethylated, Nanofibrillated Cellulose Powder for Replacement of the Nucleus Pulposus

Biocomposite hydrogels with carboxymethylated, nanofibrillated cellulose (c-NFC) powder were prepared by UV polymerization of N-vinyl-2-pyrrolidone with Tween 20 trimethacrylate as a cross-linking agent for replacement of the native, human nucleus pulposus (NP) in intervertebral disks. The swelling ratios and the moduli of elasticity in compression of neat and biocomposite hydrogels were evaluated in dependence of c-NFC concentration (ranging from 0 to 1.6% v/v) and degree of substitution (DS, ranging from 0 to 0.23). The viscoelastic properties in shear and the material relaxation behavior in compression were measured for neat and biocomposite hydrogels containing 0.4% v/v of fibrils (DS ranging from 0 to 0.23), and their morphologies were characterized by cryo-scanning electron microscopy (cryo-SEM). The obtained results show that the biocomposite hydrogels can successfully mimic the mechanical and swelling behavior of the NP. In addition, the presence of the c-NFC shows lower strain values after cyclic compression tests and consequently creates improved material relaxation properties compared with neat hydrogels. Among the tested samples, the biocomposite hydrogel containing 0.4% v/v of c-NFC with a DS of 0.17 shows the closest behavior to native NP. Further investigation should focus on evaluation and improvement of the long-term relaxation behavior.

Commingled yarn composites for rapid processing of complex shapes

Abstract Commingled yarns of reinforcing and thermoplastic fibres offer a potential for low-cost manufacturing of complex-shaped composite parts, due to reduced impregnation times and applied pressures during processing. In order to benefit from this competitive advantage, the process parameters governing consolidation must be controlled. In this study, a consolidation model, previously validated for unidirectional commingled yarn fabrics processed isothermally in a flat matched-die mould, is applied to three other processing techniques capable of producing complex-shaped composites. Tubes of braided commingled yarns were manufactured by bladder inflation moulding. Selectively reinforced polymeric parts were processed by compression–injection moulding. Stamp forming was also used to allow high-speed processing of commingled yarn-based laminates. Besides particular stamp forming cases, for which part deconsolidation occurred, the model predictions were in good agreement with the void content values obtained from specimens consolidated under different processing conditions. This suggests that the consolidation model can be successfully applied to a wide range of yarn architectures and processing techniques.

Nanohydroxyapatite/poly(ester urethane) scaffold for bone tissue engineering

Biodegradable viscoelastic poly(ester urethane)-based scaffolds show great promise for tissue engineering. In this study, the preparation of hydroxyapatite nanoparticles (nHA)/poly(ester urethane) composite scaffolds using a salt-leaching-phase inverse process is reported. The dispersion of nHA microaggregates in the polymer matrix were imaged by microcomputed X-ray tomography, allowing a study of the effect of the nHA mass fraction and process parameters on the inorganic phase dispersion, and ultimately the optimization of the preparation method. How the composite scaffolds geometry and mechanical properties change with the nHA mass fraction and the process parameters were assessed. Increasing the amount of nHA particles in the composite scaffold decreased the porosity, increased the wall thickness and consequently decreased the pore size. The Youngs modulus of the poly(ester urethane) scaffold was improved by 50% by addition of 10 wt.% nHA (from 0.95+/-0.5 to 1.26+/-0.4 MPa), while conserving poly(ester urethane) viscoelastic properties and without significant changes in the scaffold macrostructure. Moreover, the process permitted the inclusion of nHA particles not only in the poly(ester urethane) matrix, but also at the surface of the scaffold pores, as shown by scanning electron microscopy. nHA/poly(ester urethane) composite scaffolds have great potential as osteoconductive constructs for bone tissue engineering.

Nanofibrillated cellulose composite hydrogel for the replacement of the nucleus pulposus

The swelling and compressive mechanical behavior as well as the morphology and biocompatibility of composite hydrogels based on Tween® 20 trimethacrylate (T3), N-vinyl-2-pyrrolidone (NVP) and nanofibrillated cellulose (NFC) were assessed in the present study. The chemical structure of T3 was verified by Fourier transform infrared spectroscopy and proton nuclear magnetic resonance, and the degree of substitution was found to be around 3. Swelling ratios of neat hydrogels composed of different concentrations of T3 and NVP were found to range from 1.5 to 5.7 with decreasing concentration of T3. Various concentrations of cellulose nanofibrils (0.2-1.6wt.%) were then used to produce composite hydrogels that showed lower swelling ratios than neat ones for a given T3 concentration. Neat and composite hydrogels exhibited a typical nonlinear response under compression. All composite hydrogels showed an increase in elastic modulus compared to neat hydrogel of about 3- to 8-fold, reaching 18kPa at 0% strain and 62kPa at 20% strain for the hydrogel with the highest NFC content. All hydrogels presented a porous and homogeneous structure, with interconnected pore cells of around 100nm in diameter. The hydrogels are biocompatible. The results of this study demonstrate that composite hydrogels reinforced with NFC may be viable as nucleus pulposus implants due to their adequate swelling ratio, which may restore the annulus fibrosus loading, and their increased mechanical properties, which could possibly restore the height of the intervertebral discs.

Augmentation of bone defect healing using a new biocomposite scaffold: an in vivo study in sheep.

Previous studies support resorbable biocomposites made of poly(L-lactic acid) (PLA) and beta-tricalcium phosphate (TCP) produced by supercritical gas foaming as a suitable scaffold for tissue engineering. The present study was undertaken to demonstrate the biocompatibility and osteoconductive properties of such a scaffold in a large animal cancellous bone model. The biocomposite (PLA/TCP) was compared with a currently used beta-TCP bone substitute (ChronOS, Dr. Robert Mathys Foundation), representing a positive control, and empty defects, representing a negative control. Ten defects were created in sheep cancellous bone, three in the distal femur and two in the proximal tibia of each hind limb, with diameters of 5 mm and depths of 15 mm. New bone in-growth (osteoconductivity) and biocompatibility were evaluated using microcomputed tomography and histology at 2, 4 and 12 months after surgery. The in vivo study was validated by the positive control (good bone formation with ChronOS) and the negative control (no healing with the empty defect). A major finding of this study was incorporation of the biocomposite in bone after 12 months. Bone in-growth was observed in the biocomposite scaffold, including its central part. Despite initial fibrous tissue formation observed at 2 and 4 months, but not at 12 months, this initial fibrous tissue does not preclude long-term application of the biocomposite, as demonstrated by its osteointegration after 12 months, as well as the absence of chronic or long-term inflammation at this time point.

Drapability of dry textile fabrics for stampable thermoplastic preforms

Sandwiches based on stampable foam core and face sheets offer potential for cost-effective applications. Since the formability of such sandwich structures mainly depends on the drapability of the face sheets, the deformation behaviour of several types of textile preforms was evaluated. Glass fibre fabric preforms in the form of plain weave, twill, crowfoot and eight-harness satin as well as warp and weft-knitted architectures were studied. The tensile properties of the dry fabrics at various orientations and the locking angle of woven fabrics in the bias direction were determined. An analytical model is proposed to relate the fabric parameters to the locking angle. Drapability tests were performed on several woven and knitted fabrics in order to relate the forming energy to the preform architecture. Due to their high drapability and low forming energy, warp-knitted structures were selected as textile reinforcement for the sandwich face sheets.

Reaction injection pultrusion of PA12 composites: process and modelling

The development of a reactive pultrusion process is presented by considering the advantages of an in situ polymerisation of thermoplastic lauryllactam monomers. The specifics of the reaction injection unit, of the fibre-drying oven and of different pultrusion dies are given. Models were developed for the optimisation of the pultrusion process and for each processing step, namely: impregnation, polymerisation and cooling. Their individual influence on the overall pultrusion line speed was established. Heat transfer equations were solved in association with polymerisation kinetics and rheology results. Temperature profiles, conversion degrees, and viscosity changes were predicted versus composite part thickness and versus the position along the pultrusion line. Optimal mould lengths can thus be determined for optimum impregnation, polymerisation and cooling. A processing window has been defined in terms of pultrusion line speed and mould temperature. These results demonstrated with the production of profiles that reaction injection pultrusion of PA12 composites can be envisaged at larger scale.