Novel high performance polymeric composite materials for additive manufacturing of multifunctional components

Lead Research Organisation: University of Ulster
Department Name: School of Engineering

Abstract

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Description Work to date has shown that the inclusion of Inorganic Fullerene Tungsten Sulphide (IF-WS2) nanoparticles to PEEK modifies the rheology and mechanical properties such that processability by fused deposition modelling is improved and mechanical/thermal performance is also improved. A reduction in melt viscosity of 25%, and a simultaneous increase in storage modulus, crystallization and degradation temperature of about 60%, 53% and 100 °C is found with addition of 2wt% IF-WS2 to PEEK. New work with ZnO tetrapods has potential to enhance mechanical properties of these 3DP nanocomposites further.
Exploitation Route On possible use of this new material is for an aerospace bearing. Other uses include low cost, 3D printed tooling inserts for injection moulding. Potential applications in medical devices/implants.
Sectors Aerospace

Defence and Marine

Healthcare

Manufacturing

including Industrial Biotechology
 
Description - Knowldege trabsfer to the collaborative aerospace company (bombardier) for development of low wear rate bearings from PEEK with better processability and higher mechanical propertieswhich - Knowledge transfer of 3D-printing of high performance polymers and further development of new compounds and processing techniques within the engineering department at Ulster University for both medical and aerospace applications
First Year Of Impact 2019
Sector Aerospace, Defence and Marine
Impact Types Societal

Economic
 
Description Bombardier 
Organisation Short Brothers Plc
Country United Kingdom 
Sector Private 
PI Contribution Bushing component using new composite materials
Collaborator Contribution Guide on design, performance assessment etc on prototype component.
Impact New project and new collaboration just started.
Start Year 2016
 
Description Development of novel materials for AM to manufacture bushing 
Organisation Cytec Industries
Department R&D
Country United States 
Sector Private 
PI Contribution Development of new material to make a high performance bushing via additive manufacturing
Collaborator Contribution Provision of drawings for part, attending meetings
Impact New material produced. Under test. Publication in draft form.
Start Year 2016
 
Description Victrex 
Organisation Victrex
Country United Kingdom 
Sector Private 
PI Contribution Develop new composite to enhance their production line.
Collaborator Contribution Provide expensive PEEK raw materials for experiments in our project.
Impact Not yet available because of new project.
Start Year 2016
 
Description The project was described to school children in the ''Engineering Futures for primary school children'' science festival at Ulster University and samples were displayed. The children were quick to realize the importance of substituting metals/ceramics with light weight high performance polymers. Also, the concept of advanced manufacturing and its benefits was explained. 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact The Engineering Futures for primary school children was held at Ulster University in February 2024 as part of the science festival. There were two sessions each had 60 Primary School pupils (plus teachers). My research team including myself and researchers ran 15 min demonstrations and talks. They were very interested to know about 3D-printing, high-performance polymers and their benefits. They asked very interesting questions about the manufacturing and benefits. They were very aware of the importance of sustainability and recycling of plastic waste.
Year(s) Of Engagement Activity 2024