Formas Krzysztof, Janusz Jarosław, Kurowska Anna, Benko Aleksandra, Piekarczyk Wojciech, Rajzer Izabella
Department of Mechanical Engineering Fundamentals, Faculty of Mechanical Engineering and Computer Science, University of Bielsko-Biala, 43-309 Bielsko-Biala, Poland.
Department of Biomaterials and Composites, Faculty of Materials Science and Ceramics, AGH University of Krakow, al. A. Mickiewicza 30, 30-059 Kraków, Poland.
Materials (Basel). 2025 Jul 6;18(13):3192. doi: 10.3390/ma18133192.
This study consisted of the injection molding simulation of polycaprolactone (PCL)-based nanocomposites reinforced with multi-walled carbon nanotubes (MWCNTs) for biomedical implant manufacturing. The simulation was additionally supported by experimental validation. The influence of varying MWCNT concentrations (0.5%, 5%, and 10% by weight) on key injection molding parameters, i.e., melt flow behavior, pressure distribution, temperature profiles, and fiber orientation, was analyzed with SolidWorks Plastics software. The results proved the low CNT content (0.5 wt.%) to be endowed with stable filling times, complete mold cavity filling, and minimal frozen regions. Thus, this formulation produced defect-free modular filament sticks suitable for subsequent 3D printing. In contrast, higher CNT loadings (particularly 10 wt.%) led to longer fill times, incomplete cavity filling, and early solidification due to increased melt viscosity and thermal conductivity. Experimental molding trials with the 0.5 wt.% CNT composites confirmed the simulation findings. Following minor adjustments to processing parameters, high-quality, defect-free sticks were produced. Overall, the PCL/MWCNT composites with 0.5 wt.% nanotube content exhibited optimal injection molding performance and functional properties, supporting their application in modular, patient-specific biomedical 3D printing.
本研究包括用于生物医学植入物制造的、以聚己内酯（PCL）为基、用多壁碳纳米管（MWCNT）增强的纳米复合材料的注塑成型模拟。该模拟还得到了实验验证的支持。使用SolidWorks Plastics软件分析了不同MWCNT浓度（重量百分比为0.5%、5%和10%）对关键注塑成型参数的影响，即熔体流动行为、压力分布、温度曲线和纤维取向。结果证明，低CNT含量（0.5重量%）具有稳定的填充时间、完全填充模腔以及最小的冻结区域。因此，这种配方生产出了无缺陷的模块化丝状棒材，适合后续的3D打印。相比之下，较高的CNT含量（特别是10重量%）由于熔体粘度和热导率增加，导致填充时间延长、模腔填充不完全以及过早凝固。对0.5重量% CNT复合材料进行的实验成型试验证实了模拟结果。在对加工参数进行 minor 调整后，生产出了高质量、无缺陷的棒材。总体而言，纳米管含量为0.5重量%的PCL/MWCNT复合材料表现出最佳的注塑成型性能和功能特性，支持它们在模块化、针对患者的生物医学3D打印中的应用。
