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Robert Setter studied mechanical engineering at Technical University of Munich with majors in aerospace, light weight design and carbon fiber reinforced plastics. In 2017, he worked for 10 months as a visiting scholar in the field of resin-based additive manufacturing at the Polymer Engineering Center by Prof. Tim A. Osswald at the University of Wisconsin. In 2019, he wrote his master's thesis at BMW about additively manufactured injection molding polymer tools. Since March 2020, he is a research associate at the Professorship of Laser-based Additive Manufacturing by Prof. Dr.-Ing. Katrin Wudy at Technical University of Munich. He currently works in the field of innovative polymer-based additive manufacturing processes with a focus on powder- and resin-based technologies. This includes the conceptualization and development of new processes as well as the experimental analysis and characterization of polymer-based materials and additively manufactured parts.
In line with Europe's green deal, a new edition of the European action plan for a transition to a circular economy has been published in 2020. Amongst others, plastics have great potentials to achieve a high level of product circularity. In recent years, the plastics recycling industry has gained a great momentum to be one of the drivers towards a sustainable circular economy. However, there is still an abundance of challenges that need to be addressed and overcome in this sector. Therefore, a great focus in the new action plan is dedicated to plastics and plastic packaging products. Consequently, a set of mandatory or voluntary product requirements and regulations were reinforced or introduced as part of a new framework for eco-design and sustainable products. Furthermore, this legislative initiative also aims to enhance the traceability and the accessibility to product information through the implementation of certain digitalization tools, such as digital product passports (DPP). The main objective of this research is to provide a practical implementation of DPP of a pilot product made of recycled post-consumer plastic waste. It also aims to track the possible changes in the material property profile of a defined waste stream due to processing throughout the whole recycling process. High density polyethylene (PE-HD) bottle caps were selected as the targeted input waste stream. On the other end of the process, a frisbee (i.e., flying disc) was selected as the pilot product. Two collection methods were employed in this case study, namely informal and formal. The first fraction of bottle caps was collected by pupils and students (informal) over a period of two months in Upper Austria region with focus on PE-HD bottle caps. Whereas the other fraction was collected via the conventional methods (formal) and pre-sorted (1st sorting) to remove metal contaminants at the waste collection centers in Upper Austria. At the pilot plant, each fraction was hand-sorted (2nd sorting) individually to ensure a high purity of input materials. Afterwards, materials were shredded by an industrial shredder and then re-granulated using an industrial recycling extruder equipped with filtration and degassing systems. Thereafter, the resulting recyclates were injection molded into the finished frisbee. To characterize the material property profile of the different material states, several measurements including melt flow rate (MFR), differential scanning calorimetry (DSC), and mechanical tests were carried out. It was found that the informal collection led to a higher material purity as the other fraction had a more prominent melting peak of polypropylene (PP), which led to a slightly higher MFR value of this input fraction. However, no significant changes in the MFR values of the other materials were observed. In terms of the mechanical properties, the tensile stiffness and strength increased after processing. In contrast, the notched Charpy impact strength of the recyclates seemed to be slightly lower than that of both input streams.
Currently, I am working as a research engineer at Competence Center CHASE (since Feb. 2020) and, simultaneously I am a PhD candidate at Johannes Kepler University Linz, Austria. I am responsible for the characterization and testing of the recycling materials and the development of standardized quality control methods. Moreover, my responsibilities also expand to research project coordination and working together with my colleagues on the optimization of the recycling process through implementation of digitalization tools. Previously, I worked for two years at two different international companies in Upper Austria as a Quality Engineer and as a Product Engineer in the polymer and chemical sectors before I decided to shift back to research and pursue my doctorate degree in polymer technologies with focus on plastics recycling. By education, my background is a combination of industrial engineering with plastics engineering. I obtained a 5-year Bachelor of Mechanical Engineering (specialization of industrial engineering) from University of Aleppo, Syria. Afterwards, I acquired a master's degree in management in polymer technologies from Johannes Kepler University, Linz, Austria.
Samulski is emeritus Cary Boshamer Professor of Chemistry, at the University of North Carolina, Chapel Hill, where he he served as Chair of the Department of Chemistry . He is also co-founder of Liquidia Technologies, a Research Triangle start-up company based on collaborative work with UNC colleague Joe DeSimone; Liquidia went public in 2018. In 2008, he founded Allotropica Technologies, a start-up exploring new composites. In 2013, with DeSimone and Alex Ermoshkin he founded Carbon a 3D printing company located in Redwood City, CA; they have raised over $650 million binging 3D printing options to a variety of sectors. In September 2020, with his former PhD student Theo Dingemans, he's launched another company BlueSky Polymers LLC focused on high-performance polymers.
The production of conventional cross-linked polymer networks and their composites, i.e., thermosets and thermoset composites, was estimated to consume more than 40 billion kg of polymer in 2020. Unfortunately, thermosets cannot be melt-reprocessed into moderate- to high-value products because permanent crosslinks prevent melt flow. Three of many examples include rubber tires, disposed at a rate of 300 million annually in the U.S. alone, polyurethane (PU) foam, and cross-linked polyethylene, with major economic and sustainability losses resulting because the spent materials are commonly landfilled or burned for energy. Here, I will report on research demonstrating the ability to employ simple one-step or two-step reactions to produce networks and network composites with dynamic covalent crosslinks that are robust at use conditions but allow for melt-state reprocessing at elevated temperature. Unique to our research group, we have developed several approaches that allow for melt-state reprocessing of addition-type polymer networks and network composites, including those synthesized directly from monomers containing carbon-carbon double bonds, such as those used in coatings and flooring, and those synthesized from polymer or combined polymer and monomer with both containing carbon-carbon double bonds, like materials used in tires and in cross-linked polyethylene. All approaches allow for full crosslink density recovery after multiple reprocessing steps. We have also demonstrated for the first time the ability to make PU and PU-like networks, e.g., polyhydroxyurethane and polythiourethane networks, reprocessable with full recovery of crosslink density. An "Achilles' heel" has been identified regarding the application of dynamic covalent networks, i.e., such networks are subject to creep at elevated or sometimes even room temperature, which is often highly undesirable. We have addressed this limitation in two ways. In one case, we add a fraction of permanent crosslinks to dynamic covalent networks. In a second class of systems, we employ dynamic chemistry with a sufficiently high activation energy, allowing for reprocessability at high temperature but with the dynamic chemistry essentially fully arrested well above room temperature, e.g., 70-80 degrees C. Implications of these studies for making major gains in the sustainability of polymer networks and network composites will be discussed.
This presentation provides an example of comparative Life Cycle Assessment for fossil-based and bio-based polymers that are non-compostable and compostable respectively. In this instance, fossil-based and non-compostable gloves made from polyethylene were compared with our commercial bio-based and compostable gloves utilizing ISO 14040:2006, ISO 14044:2006 and ISO 22526:2020 standards. As bio-based materials are created on a much shorter timescale than fossil-fuel reserves, some consider bio-based polymers to be a form of carbon sequestration. This means that bio-based polymers can be said to have a lower feedstock carbon emission burden than fossil-based alternatives. A major discrepancy, however, when comparing fossil-based and bio-based materials largely arises due to how biogenic carbon is accounted. This normally stems from how bio-base