Melt processing of polymetric materials is a convenient and well-studied technique for forming, shaping, refining and homogenizing polymers and polymer composites. However, the large scale of traditional melt processing equipment makes it a difficult technique to adapt to the research environment. Many research and development processes which may benefit from melt processing methods are first carried out on small scale batches. This presents a problem for traditional melt-processing methods due to the large quantities required for proper extrusion and large dead volume of auger-based extruders. In the current study, we have designed, fabricated and characterized the products of a bench-top, milligram-scale melt extrusion and injection molding device, which eliminates the need for screw-based melt processing equipment, opening up this convenient technique to specialty polymers and high value-added blends in a pilot-scale setting. We achieved this desktop form factor by merging a compact pneumatic system with a small heated nozzle similar to those used on Fused Deposition Modeling 3D printers. Due to the miniaturization and ubiquity of such heated nozzles, the current design is cheap and reliable and replacement parts are commercially available rather than custom-made. A systematic approach to melt processing of PLA and PLGA polymer composites is demonstrated. Characterization of the dispersion of therapeutics and nanoparticles in melt processed polymers is presented.

Design and fabrication of a pilot-scale desktop polymer melt processing system

2019 Fall National Meeting

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