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E-Thesis 1669 views

Production of components through microcellular processing / GETHIN LLEWELYN

Swansea University Author: GETHIN LLEWELYN

  • E-Thesis under embargo until: 22nd October 2026

DOI (Published version): 10.23889/SUthesis.58862

Abstract

The manufacture of light weight plastic components is gaining relevance within thepolymer industry as component weight savings of up to 15% can be achieved. FoamInjection Moulding (FIM) is one technology solution that delivers weight savingthrough the introduction of microcellular structures within...

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Published: Swansea 2026
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Rees, Andrew ; Griffiths, Christian. A.
URI: https://cronfa.swan.ac.uk/Record/cronfa58862
first_indexed 2021-12-01T15:57:36Z
last_indexed 2021-12-11T04:25:59Z
id cronfa58862
recordtype RisThesis
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spelling 2021-12-10T11:06:03.1530830 v2 58862 2021-12-01 Production of components through microcellular processing f5f7461d2ec74a2d580a786d2db5a829 GETHIN LLEWELYN GETHIN LLEWELYN true false 2021-12-01 The manufacture of light weight plastic components is gaining relevance within thepolymer industry as component weight savings of up to 15% can be achieved. FoamInjection Moulding (FIM) is one technology solution that delivers weight savingthrough the introduction of microcellular structures within components. FIM differsfrom conventional injection moulding whereby blowing agents are added to thepolymer during processing to create a cellular structure.The first part of this research aims to benchmark Unfilled and Talc-filled CopolymerPolypropylene (PP) samples through low-pressure FIM. The research analyses theprocess response when utilising a chemical blowing agent, a physical blowing agentand a novel hybrid foaming (combination of said chemical and physical foamingagents). The experimental results concluded that Unfilled PP foams produced throughchemical blowing agent exhibited superior mechanical characteristics due to largerskin wall thicknesses. However, the hybrid foaming produced superior microcellularfoams for both PP variations due to calcium carbonate (CaCO3) enhancing thenucleation phase.The next section of research initially varied then subsequently optimised the mainprocessing parameters to determine their effect on Surface Roughness, Young’sModulus and Tensile Strength. The experimental results show that the mechanicalperformance can be improved when processing with higher Mould Temperatures andlonger Holding Times. Also, when utilising the CBA, surface roughness is comparableto conventionally processed components.The final stage of the research investigated the ability of an industry standardsimulation package to accurately predict the process response when processing with avariety of blowing agents. Initial simulations results failed to accurately replicatephysical mouldings which can be attributed to microcellular structure overestimationswithin the simulation. Through an iterative process, simulation settings have beenidentified that provide clear correlations to improve the simulation accuracy of FIM. E-Thesis Swansea Injection Moulding, Foaming 22 10 2026 2026-10-22 10.23889/SUthesis.58862 COLLEGE NANME COLLEGE CODE Swansea University Rees, Andrew ; Griffiths, Christian. A. Doctoral EngD M2A M2A 2021-12-10T11:06:03.1530830 2021-12-01T15:26:06.1184684 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised GETHIN LLEWELYN 1 Under embargo Under embargo 2021-12-01T16:37:12.7574637 Output 14628206 application/pdf E-Thesis true 2026-10-22T00:00:00.0000000 true eng
title Production of components through microcellular processing
spellingShingle Production of components through microcellular processing
GETHIN LLEWELYN
title_short Production of components through microcellular processing
title_full Production of components through microcellular processing
title_fullStr Production of components through microcellular processing
title_full_unstemmed Production of components through microcellular processing
title_sort Production of components through microcellular processing
author_id_str_mv f5f7461d2ec74a2d580a786d2db5a829
author_id_fullname_str_mv f5f7461d2ec74a2d580a786d2db5a829_***_GETHIN LLEWELYN
author GETHIN LLEWELYN
author2 GETHIN LLEWELYN
format E-Thesis
publishDate 2026
institution Swansea University
doi_str_mv 10.23889/SUthesis.58862
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 0
active_str 0
description The manufacture of light weight plastic components is gaining relevance within thepolymer industry as component weight savings of up to 15% can be achieved. FoamInjection Moulding (FIM) is one technology solution that delivers weight savingthrough the introduction of microcellular structures within components. FIM differsfrom conventional injection moulding whereby blowing agents are added to thepolymer during processing to create a cellular structure.The first part of this research aims to benchmark Unfilled and Talc-filled CopolymerPolypropylene (PP) samples through low-pressure FIM. The research analyses theprocess response when utilising a chemical blowing agent, a physical blowing agentand a novel hybrid foaming (combination of said chemical and physical foamingagents). The experimental results concluded that Unfilled PP foams produced throughchemical blowing agent exhibited superior mechanical characteristics due to largerskin wall thicknesses. However, the hybrid foaming produced superior microcellularfoams for both PP variations due to calcium carbonate (CaCO3) enhancing thenucleation phase.The next section of research initially varied then subsequently optimised the mainprocessing parameters to determine their effect on Surface Roughness, Young’sModulus and Tensile Strength. The experimental results show that the mechanicalperformance can be improved when processing with higher Mould Temperatures andlonger Holding Times. Also, when utilising the CBA, surface roughness is comparableto conventionally processed components.The final stage of the research investigated the ability of an industry standardsimulation package to accurately predict the process response when processing with avariety of blowing agents. Initial simulations results failed to accurately replicatephysical mouldings which can be attributed to microcellular structure overestimationswithin the simulation. Through an iterative process, simulation settings have beenidentified that provide clear correlations to improve the simulation accuracy of FIM.
published_date 2026-10-22T05:21:17Z
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score 11.048302

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