Integrating Exposure Assessment and Process Hazard Analysis: The Nano-Enabled 3D Printing Filament Extrusion Case

Nanoparticles are being used in novel applications of the thermoplastics industry, including automotive parts, the sports industry and leisure and consumer goods, which can be produced nowadays through additive manufacturing. However, there is limited information on the health and safety aspects during the production of these new materials, mainly from recycled sources. This study covers the exposure assessment to nano- and micro-size particles emitted from the nanocomposites during the production of filaments for 3D printing through a compounding and extrusion pilot line using recycled (post-industrial) thermoplastic polyurethane (TPU) and recycled polyamide 12 (PA12), which have been also upcycled through reinforcement with iron oxide nanoparticles (Fe₃O₄ NPs), introducing matrix healing properties triggered by induction heating. The assessment protocol included near- and far-field measurements, considering the extruder as the primary emission source, and portable measuring devices for evaluating particulate emissions reaching the inhalable zone of the lab workers. A Failure Modes and Effects Analysis (FMEA) study for the extrusion process line was defined along with a Failure Tree Analysis (FTA) process in which the process deviations, their sources and the relations between them were documented. FTA allowed the identification of events that should take place in parallel (simultaneously) or in series for the failure modes to take place and the respective corrective actions to be proposed (additional to the existing control measures).

Investigation of Carbon Fibres Reclamation by Pyrolysis Process for Their Reuse Potential

During Carbon Fibre Reinforced Polymers (CFRPs) manufacturing, large quantities of scrap are being produced and usually disposed to landfill or incinerated, resulting in a high environmental impact. Furthermore, CFRP parts that have been damaged or reached their end-of-life, follow the same disposal route and because of this, not only the environment is affected, but also high added-value materials, such as carbon fibres (CFs) are lost without further valorisation. Several recycling technologies have been suggested, such as pyrolysis, to retrieve the CF reinforcement from the CFRPs. However, pyrolysis produces CFs that have residual resin and pyrolytic carbon at their surface. In order to retrieve clean long fibres, oxidation treatment in high temperatures is required. The oxidation treatment, however, has a high impact on the mechanical properties of the reclaimed CFs; therefore, an optimised pyrolysis procedure of CFRPs and post-pyrolysis treatment of reclaimed fibres (rCFs) is required. In this study, CFRPs have been subjected to pyrolysis to investigate the reclamation of CF fabrics in their primal form. The temperature of 550 °C was selected as the optimum processing temperature for the investigated composites. A parametric study on the post-pyrolysis treatment was performed in order to remove the residues from the fabrics and at the same time to investigate the CFs reusability, in terms of their mechanical and surface properties.

Occupational Safety Analysis for COVID-Instigated Repurposed Manufacturing Lines: Use of Nanomaterials in Injection Moulding

The COVID-19 pandemic instigated massive production of critical medical supplies and personal protective equipment. Injection moulding (IM) is considered the most prominent thermoplastic part manufacturing technique, offering the use of a large variety of feedstocks and rapid production capacity. Within the context of the European Commission-funded imPURE project, the benefits of IM have been exploited in repurposed IM lines to accommodate the use of nanocomposites and introduce the unique properties of nanomaterials. However, these amendments in the manufacturing lines highlighted the need for targeted and thorough occupational risk analysis due to the potential exposure of workers to airborne nanomaterials and fumes, as well as the introduction of additional occupational hazards. In this work, a safety-oriented failure mode and effects analysis (FMEA) was implemented to evaluate the main hazards in repurposed IM lines using acrylonitrile butadiene styrene (ABS) matrix and silver nanoparticles (AgNPs) as additives. Twenty-eight failure modes were identified, with the upper quartile including the seven failure modes presenting the highest risk priority numbers (RPN), signifying a need for immediate control action. Additionally, a nanosafety control-banding tool allowed hazard classification and the identification of control actions required for mitigation of occupation risks due to the released airborne silver nanoparticles.

Mechanical Properties, Surface Assessment, and Structural Analysis of Functionalized CFRPs after Accelerated Weathering

The present study focuses on the effect of two novel carbon fibre surface treatments, electropolymerisation of methacrylic acid and air pressure plasma, on the mechanical properties and structural integrity of carbon-fibre-reinforced composites under operational conditions. Extensive mechanical testing was applied, both in nano- and macro-scale, to assess the performance of the composites and the interphase properties after ultraviolet/humidity weathering. The results of the mechanical assessment are supported by structure, surface, and chemistry examination in order to reveal the failure mechanism of the composites. Composites with the electropolymerisation treatment exhibited an increase of 11.8% in interlaminar shear strength, while APP treatment improved the property of 23.9%, rendering both surface treatments effective in increasing the fibre-matrix adhesion. Finally, it was proven that the developed composites can withstand operational conditions in the long term, rendering them suitable for a wide variety of structural and engineering applications.

An integrated approach for assessing the in vitro and in vivo redox-related effects of nanomaterials

Over the last few decades, nanotechnology has risen to the forefront of both the research and industrial interest, resulting in the manufacture and utilization of various nanomaterials, as well as in their integration into a wide range of fields. However, the consequent elevated exposure to such materials raises serious concerns regarding their effects on human health and safety. Existing scientific data indicate that the induction of oxidative stress, through the excessive generation of Reactive Oxygen Species (ROS), might be the principal mechanism of exerting their toxicity. Meanwhile, a number of nanomaterials exhibit antioxidant properties, either intrinsic or resulting from their functionalization with conventional antioxidants. Considering that their redox properties are implicated in the manifestation of their biological effects, we propose an integrated approach for the assessment of the redox-related activities of nanomaterials at three biological levels (in vitro-cell free systems, cell cultures, in vivo). Towards this direction, a battery of translational biomarkers is recommended, and a series of reliable protocols are presented in detail. The aim of the present approach is to acquire a better understanding with respect to the biological actions of nanomaterials in the interrelated fields of Redox Biology and Toxicology.

End-of-Life Recycling Options of (Nano)Enhanced CFRP Composite Prototypes Waste-A Life Cycle Perspective

Life cycle assessment is a methodology to assess environmental impacts associated with a product or system/process by accounting resource requirements and emissions over its life cycle. The life cycle consists of four stages: material production, manufacturing, use, and end-of-life. This study highlights the need to conduct life cycle assessment (LCA) early in the new product development process, as a means to assess and evaluate the environmental impacts of (nano)enhanced carbon fibre-reinforced polymer (CFRP) prototypes over their entire life cycle. These prototypes, namely SleekFast sailing boat and handbrake lever, were manufactured by functionalized carbon fibre fabric and modified epoxy resin with multi-walled carbon nanotubes (MWCNTs). The environmental impacts of both have been assessed via LCA with a functional unit of '1 product piece'. Climate change has been selected as the key impact indicator for hotspot identification (kg CO2 eq). Significant focus has been given to the end-of-life phase by assessing different recycling scenarios. In addition, the respective life cycle inventories (LCIs) are provided, enabling the identification of resource hot spots and quantifying the environmental benefits of end-of-life options.

Comparative Physical-Mechanical Properties Assessment of Tailored Surface-Treated Carbon Fibres

Carbon Fibres (CFs) are widely used in textile-reinforced composites for the construction of lightweight, durable structures. Since their inert surface does not allow effective bonding with the matrix material, the surface treatment of fibres is suggested to improve the adhesion between the two. In the present study, different surface modifications are compared in terms of the mechanical enhancement that they can offer to the fibres. Two main advanced technologies have been investigated; namely, plasma treatment and electrochemical treatment. Specifically, active screen plasma and low-pressure plasma were compared. Regarding the electrochemical modification, electrochemical oxidation and electropolymerisation of monomer solutions of acrylic and methacrylic acids, acrylonitrile and N-vinyl pyrrolidine were tested for HTA-40 CFs. In order to assess the effects of the surface treatments, the morphology, the physicochemical properties, as well as the mechanical integrity of the fibres were investigated. The CF surface and polymeric matrix interphase adhesion in composites were also analysed. The improvement of the carbon fibre’s physical–mechanical properties was evident for the case of the active screen plasma treatment and the electrochemical oxidation.

Nano-Graphitic based Non-Volatile Memories Fabricated by the Dynamic Spray-Gun Deposition Method

This paper deals with the fabrication of Resistive Random Access Memory (ReRAM) based on oxidized carbon nanofibers (CNFs). Stable suspensions of oxidized CNFs have been prepared in water and sprayed on an appropriate substrate, using the dynamic spray-gun deposition method, developed at Thales Research and Technology. This technique allows extremely uniform mats to be produced while heating the substrate at the boiling point of the solvent used for the suspensions. A thickness of around 150 nm of CNFs sandwiched between two metal layers (the metalized substrate and the top contacts) has been achieved, creating a Metal-Insulator-Metal (MIM) structure typical of ReRAM. After applying a bias, we were able to change the resistance of the oxidized layer between a low (LRS) and a high resistance state (HRS) in a completely reversible way. This is the first time that a scientific group has produced this kind of device using CNFs and these results pave the way for the further implementation of this kind of memory on flexible substrates.