Foam 3D Printing of Polylactide Systems as a Novel Simultaneous Printing and Foam Manufacturing Technology
In collaboration with University of Alberta (Canada)
Research
The key research areas at SGPL stem from Prof. Reza Nofar's goal of developing novel biopolymeric systems, sustainable lightweight multifunctional structures, and new manufacturing technologies in the field of polymer science and engineering.
Prof. Nofar has achieved outstanding progress in the area of advanced biopolymeric systems and their compounds — tackled mainly for commodity and engineering applications with energy saving and green environment aspects, as well as for biomedical applications. He has also obtained significant achievements in the field of sustainable lightweight multifunctional nanocomposites with applications in electrical devices, energy conversion/storage, and electromagnetic pollution control.
In all scientific activities and research at SGPL, the foundation is polymer processing and rheological analysis of various developed systems. In Polymer Rheology, Polymer Nanocomposites, and Sustainable Polymeric Systems, beyond primary research published in high-impact journals, Prof. Nofar has published important review articles:
Without the knowledge of polymer processing and rheology, none of the above investigations could have been successful. Prof. Nofar's scientific outputs are regularly presented at the international Polymer Processing Society (PPS) and international rheology conferences (ICR, SOR, AERC).
While the major focus of Prof. Nofar has been on polylactide / polylactic acid (PLA) — its melt processing, characterization, and improving crystallizability and melt properties — he has worked on various series of bioplastics and biocompounds for commodity and engineering applications. These include foamed PLA structures, its blends with PBAT, PBSA, PHBH, PHB, and TPU, as well as cellulose-based nanocomposites including PLA cellulose nanocrystal nanocomposites.
The expertise extends towards PBAT-based and PHA-based bioplastics and compounds, aiming to increase the use of renewable resources and reduce the carbon footprint and landfill burden of non-degradable polymers. The current aim is to tailor the durability and degradability of developed compounds for targeted applications.
Prof. Nofar and his group at SGPL conduct research on recycling thermoplastics including recycled polyethylene terephthalate (rPET), recycled polyamide, waste thermoplastic polyurethane (TPU), recycled polypropylene (rPP) and recycled polyethylene (rPE) — with the goal of recovering their original properties.
Various approaches are incorporated: mechanical and chemical recycling, various types of chain modifiers to rebuild the molecular structure, blending with other plastics, and development of microfibrillated structures from waste and recycled materials.
Prof. Nofar has contributed to the development of lightweight and cost-effective micro/nanocellular multifunctional conductive nanocomposites with tailored functional properties via controlling the distribution and orientation of conductive nanoparticles through various foam morphologies. Several high-impact scientific research and review articles have been published in this area, advancing applications in electrical devices, energy conversion/storage, and electromagnetic pollution control.
Prof. Nofar has systematically investigated the development of various thermoplastic-based blends including PLA and its nanocomposites with nanoclay, cellulose nanocrystals, nanosilica, and carbon nanotubes. The research focuses on identifying the rheological and morphological relationships in PLA-based blends and blend nanocomposites with the controlled selective localization of nanoparticles.
Book · Elsevier 2021
"Multiphase Polylactide Blends: Towards Sustainable and Green Environment"
Review · Int. J. Biological Macromolecules
"Poly (lactic acid) blends: Processing, properties and applications" — 700+ references
Prof. Nofar has obtained outstanding contributions in identifying the relationship between microcellular foam processing — foam extrusion, foam injection molding, and bead foaming — of various thermoplastics including polylactide (PLA) and its nanocomposites and blends, as well as PLA's crystallization kinetics in the presence of dissolved gas/supercritical fluids.
Prof. Nofar has also filed a patent on an innovative technology to manufacture expanded PLA bead foams. His emerging research area introduces foam three-dimensional (3D) printing as a sustainable novel route to produce microcellular thermoplastics alongside conventional foam manufacturing technologies.
Book · Elsevier 2017 (+ Chinese translation)
"Polylactide Foams: Fundamentals, Manufacturing, and Applications"
Review · Progress in Polymer Science
"Poly (lactic acid) foaming"
Sorted newest first. PI · Co-PI · Researcher
Foam 3D Printing of Polylactide Systems as a Novel Simultaneous Printing and Foam Manufacturing Technology
In collaboration with University of Alberta (Canada)
National Outstanding Researchers Program — Sustainable and Green Plastics
Development of High-Performance Microcellular aPLA–cPLA Bioplastic Foam Structures with Superior Melt Strength
In collaboration with University of Toronto (Canada)
Scientific and Technological Research Projects — Environmentally Friendly Sustainable Advanced Automotive Technologies
Development of PLA, PBAT, PLA/PBAT Nanocomposites Using Chemically Modified Cellulose Nanocrystal (CNC) Structures
Development of New-Generation Conductive Multifunctional 3D-Fibrillated PTFE / Multi-Walled Carbon Nanotube (MWCNT) Additives
Production of Tailor-Made Polyethylenes (PE) and Ethylene-Based Thermoplastic Polyolefin Elastomers (TPO) by New Constrained Geometry Post-Metallocene Catalysts
Design of Temperature-Resistant Recycled PET/PBT Bead Foams and Clarification of Structure–Property Relationships when Foaming and Welding
In collaboration with University of Bayreuth (Germany)
Development of Zeolite–PLA Films for Food Protection Applications
Development of Surface Chemical Modification of Cellulose Nanocrystal to Enhance Dispersion within PLA, PBAT, and PBSA Bioplastics
Development of High-Viscoelastic and Processable Polylactide and its Carbon Nanotube Reinforced Nanocomposites through Fibrillated Crystal Network Generation
Development of Innovative and Functional PLA–TPU In-Situ Nano/Microfibril Composites
In collaboration with Polytechnique Montréal (Canada)
Development of Nano-Modified Super-Tough PLA-Based Biopolymeric Blend Nanocomposite Systems
Development of Super-Tough Ternary Blends and Blend Nanocomposites
Development of Microcellular Expanded Thermoplastic Polyurethane Bead Foams: Dependency of Foam Structure on TPU Molecular Weight and Configuration
Development of PLA-Based Blend Nanocomposites with Controlled Morphology Using Clay Nanoparticles