The present invention relates to the use of thermoplastic polymer compositions for impregnating reinforcing materials in the form of fabric or industrial fabrics for the manufacture of composite materials. The field of the invention is that of composite materials as well as molding/consolidation processes and obtained parts. The invention more particularly relates to a method of manufacturing a composite article by injection molding comprising at least the steps of introducing at least one reinforcement fabric into a preheated mold, partial closure of the mold, a temperature rise step of the mold, optionally a step of maintaining the temperature of the mold before injection of a thermoplastic polymer composition, a step of injecting a thermoplastic polymer composition into the mold, a step of mold closure to the final part thickness allowing the flow of the resin through the reinforcing fabric, a cooling step and a recovery step of the obtained composite article.

A method is disclosed for micro-molding articles. The method comprises melting and pre-pressurizing thermoplastic material to a first level, within a plasticizing barrel. The melt pressure of the thermoplastic material is manipulated to a second level, within a hot runner. The melt pressure of the thermoplastic material is manipulated to an ultra-cavity packing pressure within a valve gate nozzle.

Ways of preparing a partially crystalline polycarbonate powder are provided that include dissolving an amorphous polycarbonate in a polar aprotic solvent to form a first solution of solubilized polycarbonate at a first temperature. The first solution is then cooled to a second temperature, the second temperature being lower than the first temperature, where a portion of the solubilized polycarbonate precipitates from the first solution to form a second solution including the partially crystalline polycarbonate powder. Certain partially crystalline polycarbonate powders resulting from such methods are particularly useful in additive manufacturing processes, including powder bed fusion processes.

Ways of preparing a partially crystalline polycarbonate powder are provided that include dissolving an amorphous polycarbonate in a polar aprotic solvent to form a first solution of solubilized polycarbonate at a first temperature. The first solution is then cooled to a second temperature, the second temperature being lower than the first temperature, where a portion of the solubilized polycarbonate precipitates from the first solution to form a second solution including the partially crystalline polycarbonate powder. Certain partially crystalline polycarbonate powders resulting from such methods are particularly useful in additive manufacturing processes, including powder bed fusion processes.

Aspects of the disclosure relate to methods for making large areas of high aspect ratio micro or nanostructured foil using existing extrusion coating equipment. A method is disclosed for producing a high aspect ratio micro- or nanostructured thermoplastic polymer foil, or a nanostructured thermoplastic polymer coating on a carrier foil, comprising at least one high aspect ratio nanostructured surface area. The method comprises applying a high aspect ratio nanostructured surface on an extrusion coating roller and maintaining the temperature of the roller below the solidification temperature of the thermoplastic material. A thermoplastic foil and a thermoplastic coating made by the method is also disclosed.

A method of blow molding an article having at least one layer of thermoplastic material. The method comprises the steps of heating a mold having an inner surface with two or more areas of different surface textures to a first temperature of greater than 55° C. and subsequently feeding a parison into the mold. The parison is then blown against the inner surface of the mold to form an article. The temperature of the mold is subsequently lowered to a second temperature of between 20° C. to about 55° C. and the temperature cycle time (t.sub.ct) of the mold is less than 250 seconds. Using the two phase heating and cooling process in combination with a mold featuring different surface textures provides a finished article with different visual effects.

An example of a three-dimensional (3D) printing kit includes a build material composition and a fusing agent to be applied to at least a portion of the build material composition during 3D printing. The build material composition includes a semi-crystalline thermoplastic polymer having a surface energy density greater than 41 mN/m. The fusing agent includes an energy absorber to absorb electromagnetic radiation to coalesce the semi-crystalline thermoplastic polymer in the at least the portion.

A pre-preg product, such as a tape or sheet suitable for forming a composite having reinforcement fibers and a liquid crystal thermoset (LCT) precursor is provided. Further aspects of the invention are directed to a method for preparation of the pre-preg product and to composite products based on the pre-preg product.

An example method for cooling a build volume is described. In one implementation, a heating mechanism is set to a temperature identified based on the build material information, and the build volume is heated using the heating mechanism for a time period identified based on the build material information.

Nano-composite films and methods for their fabrication. The nano-composite films include a polymer matrix (e.g., polyethylene, polypropylene, or the like) and a filler capable of exfoliation such as graphene or hexagonal boron nitride (e.g., TrGO). The filler provides reinforcement, increasing tensile strength, Young's modulus, or both for the resulting nano-composite film, as compared to what it would be without the filler. The nano-composite film may have a specific tensile strength that is greater than 1 GPa/g/cm.sup.3, a specific Young's modulus that is greater than 100 GPa/g/ccm.sup.3, or both. Tensile strength and modulus values of up to 3.7 GPa/g/cm.sup.3 and 125 GPa/g/cm.sup.3, respectively, have been demonstrated. The film maybe formed by combining powdered filler and polymer matrix powder in a solvent (e.g.,decalin), high-shear extruding the resulting solution to disentangle the polymer chains and exfoliate the filler, freezing the solution to form a solid film, and then drawing the film.