Compression Moulding Research Articles

Qualitative Evaluation of Relation between Mixing Uniformity of Binder and Strength of Compression Molded Tablet

Qualitative Evaluation of Relation between Mixing Uniformity of Binder and Strength of Compression Molded Tablet

Effects of polycaprolactone viscosity on morphology, mechanical properties, water uptake, and cellular viability in poly(3‐hydroxybutyrate)/polycaprolactone blends for tissue engineering

AbstractIn this study, two polycaprolactones (PCLs) with different molar masses were evaluated regarding their influence on the melt processability, morphology viscoelastic and mechanical properties, water uptake, and fibroblast and pre‐osteoblast viability of poly(3‐hydroxybutyrate)/polycaprolactone (PHB/PCL) blends. PHB/PCL blends were prepared in a mixing chamber following 90/10 and 70/30 ratios and later compression molded. The torque rheometry results show that the blends' processability is influenced by the ratio and molar mass of the PCL used in its obtaining, those being more strongly affected by the PCL with lower molar mass. The results indicate that the polymeric blend was immiscible in any proportion and molar mass of PCL used. The blends showed a sea‐island morphology in which the diameter of the dispersed phase depended on the composition. In general, even though the molar mass of PCL differed, the blends showed similar behaviors. However, a great difference was observed in the fracture mechanism for the blend with PCL of lower molar mass, which did not present the ability to fibrillate before rupture, due to its low mechanical resistance. The blends showed greater water uptake capabilities when compared to the pure polymers due to the diffusion of water through the gaps in between the phases. The blends showed high cell viability when tested in fibroblast cells of the L929 lineage and pre‐osteoblast cells of the MCT3‐E1 lineage, indicating that these materials are promising for application in bone tissue engineering.

Phosphorescence and Tarnish Resistance Properties of Copper with Strontium Aluminate Addition

The purpose of this research is to examine the effect of strontium aluminate (SrAl2O4) in copper samples on phosphorescence and tarnish resistance properties. The samples were fabricated by powder metallurgy using the compression moulding technique and then sintered in argon atmosphere. Phosphorescence, hardness, microstructure and tarnish resistance were studied. In the process of the compression moulding, the samples contain 100, 90, 80 and 70 percent of copper powder, by weight, with the addition of 0, 10, 20 and 30 percent of strontium aluminate, by weight, respectively. Polyvinyl alcohol (PVA) was used as a binder and mixed with copper and strontium aluminate powder to produce the green specimens using a hydraulic machine. Then, the green samples were sintered at 900 °C for one hour. After sintering, PVA was eliminated and the samples became denser. It was found that the hardness of the sample without strontium aluminate (30.5 HV) is higher than that of the sample with 10% of strontium aluminate addition (12.84 HV). Furthermore, copper samples containing strontium aluminate were fluorescent under ultraviolet at 517 nm. The sample with the largest amount of strontium aluminate (70Cu-30SrAl2O4) has higher phosphorescence than 90Cu-10SrAl2O4. In sulphur atmosphere, the tarnish resistance was found to be improved when strontium aluminate was added into copper. The colour difference (DE*) of 100Cu, which has no strontium aluminate, was 6.42 and higher than that of 90Cu-10SrAl2O4 (DE*= 3.5), 80Cu-20SrAl2O4 (DE*= 1.37), and 70Cu-30SrAl2O4 (DE*= 0.49), when testing in sulphur atmosphere for 30 min. 70Cu-30SrAl2O4, containing the highest amount of strontium aluminate, has the least colour changing on its surface resulting in the resistance in tarnishing.

Comparison of FDMed and compression molded biocomposites in polylactic acid and food flour waste

Polylactic acid resins are some of the most largely used bioplastics, some characteristics still limit their use, such as in mixing with other polymers or inclusion of additives. Currently, additive manufacturing technologies are enlarging their application sectors because they allow more rational use of raw materials, limiting both production waste and onerous post-processing stages. In this framework, polylactic acid resins, particularly favoured by their slow crystallization rate and the large availability, are some of the most used to obtain commercial filaments for fused deposition modeling. This research is then focused on the processability of the compounds, based on a commercial PLA resin, additivated with 1, 3, and 5 wt% of food flour wastes. The comparison of the performance of the products obtained with conventional and innovative technologies, respectively compression molding and FDM, is the key point of this study. Mechanical and morphological properties, obtained by the two technologies, were evaluated for neat and additivated resins. Preliminary results emphasize that, through compression molded, it was possible to obtain homogeneous components and the natural infilled used acts as reinforcement improving mechanical performances. For the additive technology, the samples obtained show a lower mechanical behavior due to the technological issues of 3d printing.

Polyhydroxybutyrate-co-hydroxyvalerate (PHBV) with Phenolic Acids for Active Food Packaging.

PHBV films incorporating 3, 6 and 9% ferulic acid (FA) or p-coumaric acid (PCA) were obtained by melt blending and compression moulding. The films' microstructures and thermal behaviours were analysed as well as their mechanical, optical and barrier properties. The overall and specific migration of the materials in different food simulants was also characterised. FA was homogeneously mixed with the polymer, whereas PCA was mainly dispersed as fine particles in the PHBV matrices due to its higher melting point. These structural features promoted differences in the physical properties of the films depending on the compound concentration. As the concentration of both compounds rose, the barrier capacity of the films to oxygen, and to a lesser extent water vapour, was enhanced. While FA promoted the extensibility of the films, 9% PCA enhanced their brittleness. Both compounds affected the crystallisation pattern of the polymer, promoting smaller crystalline formations and a slight decrease in crystallinity. Although the overall migration of every film formulation was lower than the overall migration limit (OML), the release of active compounds was dependent on the food simulant; almost total release was noted in ethanol containing simulants but was more limited in aqueous systems. Therefore, these films could be used as food contact materials, contributing to extending the food's shelf life.

Structural composite batteries made from carbon fibre reinforced electrodes / polymer gel electrolyte prepregs

Full cells of structural composite batteries comprising carbon fibre reinforced anodes and cathodes decorated with lithium titanate and LiNi0.3Mn0.3Co0.3O2 (NMC111), respectively, embedded in a polymer gel electrolyte were produced. Spread carbon fibres were coated with cathode and anode active materials followed by impregnation with a polymer gel electrolyte consisting of PVDF particles dispersed in an ionic liquid containing a lithium salt. The resulting carbon fibre reinforced electrodes/polymer gel electrolyte prepregs could be easily stored, handled or, if needed, transported. Cathode and anode prepregs were laminated and fused by compression moulding, resulting within a time frame of couple of minutes in full cell structural composite batteries. The batteries were charged and discharged at current densities of 0.1C, resulting in a specific capacity of 35 mAh/gNMC111 and energy density of 5.6 Wh/(kg battery). The composite batteries had a Young's modulus of 4.6 GPa and tensile strength of 32 MPa. A facile layup process enabled proof-of-concept demonstration of ‘all’ carbon fibre full cell multifunctional structural composite batteries.

Preparation and characterization of short date palm mat (DPM) fiber reinforced polystyrene composites: Effect of gamma radiation

The utilization of natural fiber reinforced polymer composites is growing fast in numerous sectors. In this study, the effect of the addition of short date palm mat (DPM) fibers in polystyrene matrix on the physico-mechanical and thermal properties were studied. Short DPM fiber reinforced polystyrene composites were produced by compression moulding process and the fiber content was 5, 10, 15, 20 and 25 wt%. Physico-mechanical and thermal properties were examined. Scanning electron microscopy (SEM) and Fourier-transform infrared (FT-IR) analysis of the composites were also done. The findings from the investigates exposed that the composites with 10 % fiber content showed improved mechanical and thermal characteristics as compared to other composites. The morphological analysis also supported the results where good interfacial bonding among fiber and polystyrene matrix was found for the composites with 10 % fiber content. The optimized (10 % fiber content) composites were exposed to gamma radiation (2.5–7.5 kGy) and the best result was found at 5.0 kGy radiation dose. Degradation of gamma irradiated composites was conducted in four different media such as water, acid, base, and brine.

The effect of alkali treatment on the mechanical properties of date seed particulates waste polypropylene filled composites

Date seeds collected as waste were reduced to 63 µm particles and treated with NaOH (aq) at 1, 3, 5, 7 and 10 %. The extent of chemical modification was assessed using FTIR analysis. The waste polypropylene (wPP)/date seed particles (DSP) composites filled with untreated and treated particles at 20 % filler loadings were fabricated using compounding and compression moulding techniques by means of two rolls mill. Tensile, flexural, impact tests and hardness (HV) were conducted and evaluated. Subsequently, a morphological study of the fractured surface of the composites was achieved using SEM. The application of alkali treatment enhanced various properties of the composites at the optimal concentration of 10 % w/v. Specifically, the tensile strength, flexural strength, elongation at break, impact strength, and hardness were improved, resulting in values of 28.86 MPa, 140 MPa, 172.5 %, 0.92 J/m², and 23.8 Hv, respectively. While tensile and flexural moduli showed a decrease with increasing alkali concentration. The SEM of the fractured surface of the treated composite revealed a better dispersion of filler particles within the matrix with no cluster seen compared to the untreated.

An examining the static and dynamic mechanical characteristics of milled ramie root reinforced polyester composites

This research works discuss about the effective utilization of waste Ramie Root, that has been in reinforced polyester composites, powdered fillers that have not been treated are used. Four different composites plate were formed with compression moulding technique process consisting of 20, 30 and 40% of Powdered Ramie Root with 80, 70 and 60% unsaturated polyester resin, respectively. The maximum mechanical properties were observed for the composite with 30:70 weight volume percentages of milled ramie root synthetic reinforced polyester. The findings show that the glass transition temperature, storage modulus, and loss factors all rise when the composition of composites changes. Additionally, the powder cohesion force (bonding strength) has a greater impact on dynamic mechanical properties. Thermo-gravimetric the inclusion of Ramie Root powder caused the thermal deterioration peak of the composite to move from 370 °C to 418 °C, according to analysis (TGA) conducted under flowing oxygen. According to the measurement of water absorption, the ideal weight ratio of Fiber: Unsaturated Polyester Resin is 30:70, which modifies the fibres’ surfaces and ensures optimal adhesion between the fibre and matrix in composite materials. Scanning electron microscopic investigation is done to ascertain the fracture behaviour of the composite. As a result of their stability, high tensile strength, and bending stiffness, the produced composites can be used in light-load applications by material technologists.

Experimental and numerical investigation of the intra-ply shear behaviour of unidirectional prepreg forming through picture-frame test

Intra-ply shear behaviour of uncured composite plies strongly influences component quality in advanced manufacturing processes such as prepreg compression moulding (PCM) and double diaphragm forming (DDF). This study investigates a straightforward method to characterise the intra-ply shear behaviour of a carbon fibre/epoxy UD prepreg using a specially designed picture-frame rig, by which specimens can be tested without involving inter-ply shear as would normally be observed in cross-plied UD prepreg stacks. Applying the proposed method, it is seen that specimens tend to suffer transverse buckling/wrinkling and local fibre-splitting at large shear strains. 3D digital image correlation (DIC) and a non-contacting video extensometer were utilised to determine the shear strain distribution throughout the test and particularly to determine the onset of out-of-plane deformations such that the trellis shear deformation portion of the test can be identified. The obtained shear stress-strain results show a temperature- and rate-dependent viscoelastic response, with the greatest influence from the temperature. The obtained in-plane shear properties were applied in the numerical simulation of the picture frame test based on a hypoelastic law. Although the predicted reaction forces are greater than experimental results at high strains due several factors including local fibre-splitting, a good agreement overall between physical test data and simulation results is seen for all test conditions. Finally, it is demonstrated that major advantages of the proposed test with respect to the conventional picture-frame test are that only load-extension data are required from the trellis shear experiment to calculate accurately the intra-ply shear stress-strain relationship and that the deformation rate can be easily controlled.

Optimizing the water absorption behaviour and natural weathering resistance of compatibilized ironwood-based recycled polypropylene composites

This study focused on the optimization of material resistance of wood-plastic composite (WPC) made using recycled polypropylene and industrial ironwood residues toward water and natural weathering exposure. The Taguchi method was employed to optimize the WPC composition and manufacturing process parameters based on the L9 orthogonal array experimental design. The WPC specimens were prepared using two-step of extrusion compounding and compression moulding. As input process parameters, ironwood content, coupling agent content, moulding temperature, and pressure holding time have been taken into consideration. The results were then optimized to get the maximum tensile properties of strength and modulus of elasticity as well as minimum water-weight gain and discolouration area after exposure to water immersion and natural weathering. The grey relational analysis (GRA) was carried out to identify the most significant factors and optimal levels that work synergistically to produce enhanced results. For optimizing the performance after water uptake, the ironwood content and moulding temperature are the most significant parameters with percentage contributions of 48.71% and 43.16%, respectively. Meanwhile, the multi-objective optimization technique of GRA obtains that ironwood content is the most significant factor for optimizing the mechanical and physical performance of the WPC after exposure to natural weathering with a percentage contribution of about 71%. Considering the good resistance of the material toward environmental exposure, this study opens up a pathway to effectively utilize ironwood and recycled polymer waste as a sustainable composite material in outdoor applications.

Prospects for manufacturing of complex 3D-shaped all-cellulose composites

All-cellulose composites (ACC) have been investigated as a high-strength bio-based alternative to commodity plastics. However, plastic products frequently demand complex 3D geometries as part of their functionality. Hence, a critical factor in the broader application of ACCs is the production of dimensionally-accurate 3D forms. Interestingly, there have been no attempts in the literature to produce 3D geometries based on all-cellulose composites. In the present work, the production of ACCs with 3D geometries is explored for the first time using conventional vacuum and compression moulding procedures. The level of 3D complexity possible in ACCs was examined using a closed mould design that incorporated a range of geometric shapes and angles of varying intricacy. The dimensional accuracy of the final 3D forms was analysed via 3D laser scanning of the surfaces of the as-moulded ACCs. The choice of coagulant type was found to strongly influence the dimensional accuracy of the as-moulded ACCs.

Fabrication and characterization of weld attributes in hot gas welding of alkali treated hybrid flax fiber and pine cone fibers reinforced poly-lactic acid (PLA) based biodegradable polymer composites: studies on mechanical and morphological properties

The contemporary times have witnessed a lot of interest in fabricating green composites because of its biodegradability, durability, affordability, ease of manufacturing and its potential to replace existing commercial goods in the field of engineering applications. The green composites are envisaged to replace synthetic polymer-based composites since the green composites are fabricated using the biodegradable polymers reinforced with natural fibers. In this research work, Flax Fiber and Pine Cone Fibers are reinforced in Poly-lactic Acid (PLA) matrix. The green composites are fabricated using compression moulding technique in different nominations as per the weight fraction such as (90:10), (80:20) and (70:30). It was noticed that a higher tensile strength of 27 MPa is observed in case of group 2 (80:20) specifically for the composite having 80% of matrix and 14% flax and 6% pine cone fibers. An IoT based automatic hot gas welding method was used to join the fibers by considering various input parameters like stand of distance, weld rate, specimen groove geometry, and composition. The mechanical testing of the weld specimens was carried. It was observed that the weld joints having higher stand of distance were observed to have less tensile strength as compared to others and the fracture points of such specimens were observed to be at the weld bead. SEM analysis of the fracture point validated the observations from the mechanical characterization.

Investigating the Integration of Nonwoven Carbon Fibers for Mechanical Enhancement in Compression Molded Fiber-Reinforced Polymer Bipolar Plates.

The demand for polymer composite solutions in bipolar plates for polymer electrolyte membrane fuel cells (PEMFCs) has risen due to advantages over metal plates such as longer lifetime, weight reduction, corrosion resistance, flexible manufacturing, freedom of design, and cost-effectiveness. The challenge with polymer composites is achieving both sufficient electrical conductivity and mechanical stability with high filler content. A carbon fiber fleece as reinforcement in a graphite-filled polypropylene (PP) matrix was investigated for use as bipolar plate material with increased mechanical and sufficient conductive properties. Plates with a thickness of 1 mm containing four layers of fleece impregnated in the PP-graphite compound were produced in a compression molding process. Particle and fiber interactions were investigated via microscopy. The plates were characterized with respect to the electrical conductivity and mechanical stability. High electric conductivity was reached for fiber-reinforced and plain PP-graphite compound plates, with increased filler content leading to a higher conductivity. The contact resistance remained largely unaffected by surface etching as no polymeric skin layer formed during compression molding. Fiber-reinforced plates exhibit twice the tensile strength, a significantly higher tensile modulus, and an increased elongation at break, compared to PP filled only with graphite.

A novel recycling framework for transforming uncured aerospace prepreg offcuts into a strand-based compression moulding compound with adjustable flow-compaction and curing behaviours

Aerospace composites manufacturers discard anywhere from 30 to 50% of their uncured prepreg during the ply-cutting phase of manufacturing. This waste is attributed to nesting pattern inefficiencies caused by restrictive production schedules, fixed prepreg roll widths, and limited material out-life. Previous studies have explored the possibility of transforming offcuts into strand-based compression moulding compounds, but have been limited by the processing mismatch between autoclave curing and compression moulding. This article introduces a recycling framework which employs comprehensive material characterization and targeted elevated temperature staging to produce a recyclate with tailorable processing characteristics without the need for additional resins or fillers. The influence of resin viscosity on prepreg flow-compaction is presented and a software tool is introduced which generates process maps for selecting optimal staging based on desired moulding temperature, cure time and resin viscosity.

Development of cashew nut shell lignin-acrylonitrile butadiene styrene 3D printed core and industrial hemp/aluminized glass fiber epoxy biocomposite for morphing wing and unmanned aerial vehicle applications

The aim of this study was to develop a lightweight epoxy based biocomposite for morphing wing and unmanned aerial vehicle (UAV) applications. The proposed composite was developed using a 3D printed high stiffness lignin-Acrylonitrile Butadiene Styrene (ABS) core and industrial hemp with aluminized glass fiber epoxy skin. The ABS was reinforced using lignin macromolecule derived from cashew nut shells via twin screw extruder and the core was printed using an industrial grade 3D printer. Furthermore, the composites were prepared by compression moulding with an ABS-lignin core and hemp/aluminized GF surface and characterized according to respective American society of testing and materials (ASTM) standards. The findings indicate that the addition of 30 vol% Al-glass and hemp fiber with lignin strengthened ABS core improved the mechanical properties. The composite material designated as “E2” exhibits the maximum mechanical properties, providing tensile strength, flexural strength, Izod impact, interlaminar shear strength (ILSS), and compression values of, 136 MPa, 168 MPa, 4.82 kJ/m2, 21 MPa, and 155 MPa respectively. The maximal energy absorbed by composite designation “E2,” during drop load impact test is 20.6 J. Similarly, the composite designation “E2”gives fatigue life cycles of 33,709, 25,781 and 19,633 for 50 %, 70 % and 90 % of ultimate tensile strength (UTS) and 32.5 (K1c) MPa⋅m and 0.76 (G1c) MJ/m2 in fracture toughness and energy release rate respectively.

Characteristic properties of date-palm fibre/sheep wool reinforced polyester composites

In this study, we attempted to characterise the effects of date-palm fibre (DPF) and a date-palm fibre/sheep wool hybrid in polyester to enhance high-performance and low-cost composite materials that can be used in insulation building systems, automotive parts, and home furniture. The DPF was treated using 5 % NaOH solution; and the sheep wool was cleaned with 50 °C hot water and detergents. The composite specimens were prepared with different fibre contents (0 %, 10 %, 20 %, 30 % (w)) using a compression moulding technique. The effect of fibre reinforcement was analysed in terms of the mechanical properties (tensile, flexural, impact, and hardness) and composite density. Additionally, scanning electron microscopy (SEM) was performed on the fibres before and after treatment, and the fractured surfaces of all composite specimens were examined after tensile testing. The results showed that the 20 % DPF/sheep wool hybrid reinforced polyester produced the best results. The ultimate tensile strength and modulus were 27 MPa and 3.69 GPa, respectively. The ultimate flexural strength and flexural modulus were 35.4 and 2507 MPa, respectively. The impact strength was 39.5 kJ/m2 and the hardness was 64 HB. The density decreased to the lowest value of 1.02 g/cm3 with the 30 % DPF/sheep wool hybrid. The SEM showed good adhesion and interfacial bonding between DPF/sheep wool hybrid fibres and the polyester matrix, particularly at 20 % fibre content.

Mechanical Properties of Bio-Based Sandwich Composites Containing Recycled Polymer Textiles.

In this paper, sandwich composites were produced by compression moulding techniques, and they consisted of regenerated cellulose fabric (rayon) and bio-based polypropylene (PP) to form facings, while virgin and recycled polyamide (PA) textiles were used as core materials. To compare the mechanical performance between sandwich composites and typical composite designs, a control composite was produced to deliver the same weight and fiber mass fraction from rayon and PP. To evaluate the influence of recycled textile on the mechanical properties of the composites, a series of flexural, low velocity impact (LVI) and tensile tests were performed. It was found that the incorporation of thicker PA textile enhanced the bending stiffness by two times and the peak flexural force by 70% as compared to those of control. Substitution of a layer of recycled textile for two layers of rayon provided a good level of impact energy absorption capacity (~28 J) and maximum force (~4893-5229 N). The tensile strength of the four sandwich composites was reported to be in the range of 34.20 MPa and 46.80 MPa. This value was 91.90 for the control composite. The 2D cross-section slices of the composite specimens did not show any evidence of fiber tow debonding, fiber bundle splitting, or delamination.

The effects of zircon particles on the mechanical and morphological properties of glass fibre reinforced epoxy composite

Recent studies have focused on improving the mechanical properties of thermosetting composites that seem to include inorganic nanoparticles dispersed throughout the matrix material. This study investigates the mechanical properties, crystallographic and morphological study of epoxy composites when ball-milled zircon filler is incorporated into epoxy at weight percentages of 0, 5, 10, and 15(wt%). Zircon nanoparticles and epoxy resin are blended using an ultrasonic liquid technique, and then compression moulding is used to make the composite materials. Using theoretical and calculated densities (g/cm3), the volume fraction of voids (%) in the prepared composites is estimated. The Mechanical tests were done in accordance with ASTM requirements. The average zircon particle size was found to be 73.26 nm using field emission scanning electron microscopy. The chemical composition, crystalline structure and the crystalline size (2.1 nm) of zircon particle was determined using X-Ray diffraction. In comparison to pure glass fibre reinforced epoxy polymer, the 10 wt% zircon particle's tensile strength, tensile modulus, flexural strength, and flexural modulus are 33.33%, 12.56%, 32.88%, and 15.74% higher, respectively. Strain energy for tensile test is 82.96%, elongation at break is 53.52% higher and strain energy for flexural test is 52.38%, elongation at break is 14.67% higher than pristine composites. As a comparison to neat sample, Shore "D" hardness at 10 wt percent ZrSiO4 is 5.88% harder, and Izod average impact strength (J/mm) is 63.20% greater. Pullout of fibre, damaged interfaces, filler dispersion and voids are identified using field emission scanning electron microscopy. Zircon filler of 10 wt% inclusion on epoxy with E-glass fibre reinforcement reportedly improves characteristics than other proportions, especially better improvement than plain sample. Because of this, the mechanical and structural properties of developed composites are enhanced by this approach. This research proposal would lead to a special combination of ZrSiO4 inclusion and E-glass fibre reinforcement in epoxy composites for aircraft structural applications.

Circular, zero waste formwork - Sustainable and reusable systems for complex concrete elements

The construction sector contributes significantly to global carbon emissions, leading to a new need and demand for sustainable and material-efficient construction technologies. Digital form-finding, simulation, and optimization methods are advancing, resulting in highly efficient, but often geometrically complex components. Concrete construction, which is currently dominant worldwide and crucial for sustainable material savings due to its large market volume, still faces challenges in implementing complex geometries. The significant requirements for formwork material and limitations in feasibility and cost at the current state of the art contribute to these challenges. This research presents a zero waste process using recyclable and reusable digitally fabricated formwork made from waste ingredients that can be immediately implemented in the construction industry. Residual sands (quartz and ceramics) were investigated as a basic moulding material in combination with biogenic binders (bentonite, eco-resin, sodium silicate, starch) for the production of stable formwork composites. The material compound were shaped into precise complex forms using 5-axis milling, and the removed material was recycled in a closed material cycle. Testing and characterization methods for evaluating mechanical properties such as compressive forces (20.1 N/mm2), surface roughness (Ra 9.1 μm), tolerances (0), and moulding processes indicate that the presented procedure conforms to common industry standards. Demonstrating feasibility, complex ultra-thin 1:1 concrete prototypes were designed and manufactured under industrial conditions using prefabricated formworks made of researched bio composite. The resulting high-resolution formwork surfaces and exposed concrete precast elements correspond to the highest fair-faced concrete class (SB04), with line roughness values of Ra 14.4 μm. The developed circulation concept allows reproducibility of different geometries and repeated concreting of formwork moulds. The formwork process is free from harmful additives, enabling recycling through grinding and reintegration into a closed material cycle. Sustainability has been continuously monitored and evaluated through a life cycle assessment. This system utilizes standard machines and offers an accessible and easily integrated approach for a holistic zero waste solution, suitable for efficient industrial applications.