Grant: Discovery Grants Program - Individual

Additive manufacturing (AM) is revolutionizing the manufacturing world due to the numerous advantages it offers. This technology allows the creation of custom-made designs with very complex and innovative geometries, which find applications in various industries such as aerospace, automotive and pharmaceuticals. Additionally, it significantly reduces the reliance on traditional tooling, facilitating rapid prototyping and expediting the design of structures and devices. Moreover, it minimizes waste when compared to conventional manufacturing methods and can make use of recycled polymers. When AM is coupled with polymer blends (PB) or nanocomposites (PNC), it unlocks even more advantages, as these materials synergistically combine the properties of their components. However, when working with multiphase materials like PB and PNC, it becomes crucial to control the evolution of their morphology during processing, as it directly influences their functional properties. Maintaining the stability of the morphology during processing is essential to prevent undesirable changes in functional properties. Unfortunately, most of the studies that have dealt with AM of PB and PNC have looked more at the final properties of the printed object rather than at the control of the evolution of morphology and the influence that it has on the engineering properties of the printed object, underestimating the importance of this aspect. Therefore, the objective of this research program it to create tools that can effectively manage the morphology of PB and PNC during AM process, ultimately resulting in the attainment of optimal functional properties of the printed products. To achieve this goal, our efforts will be directed towards two primary areas: the manufacturing process itself and the materials involved. On the process front, we intend to develop phenomenological models that describe how the morphology of blends and composites evolves during extrusion-based additive manufacturing, using two different AM machines recently acquired through a CFI grant. On the materials front, we plan to develop tools and techniques for stabilizing the morphology of PB and PNC utilizing modified nanoparticles. This knowledge will empower us to create morphology gradient materials and to produce printed objects, constructed from blends composed of post-consumer recycled polyolefins. The program will involve the participation of at least 10 HQP and will reinforce collaborations with researchers from Canada, France, Germany, Luxembourg and Brazil. This is highly beneficial for HQP. Indeed, studying abroad exposes individuals to diverse cultures and perspectives, fostering empathy and understanding for different cultural backgrounds. This immersion encourages embracing principles of equity by appreciating everyone's experiences and contributions. The experience also promotes inclusivity, as students learn to collaborate with peers from various cultures.