Vacuum Thermoforming Research Articles

Bonding positional accuracy of attachments and marginal adaptation of in-house aligners - A quality improvement laboratory study.

To evaluate the 3D accuracy of attachment positioning and the adaptation of aligners to attachments using in-house templates made with either polyethylene terephthalate glycol (PETG) or ethylene-vinyl acetate (EVA) and either pressure or vacuum thermoforming machines. Overall, 140 test specimens were resin-printed. Templates for the attachment bonding were made with 1-mm EVA or 0.5-mm PETG laminates. Orthodontic aligners were manufactured with 0.75-mm PETG. The thermoplastification process was carried out using either vacuum or pressure machines. The positional differences between the virtual and bonded attachments were assessed in the X, Y and Z coordinates. The marginal adaptation between the aligners and the attachments was measured. Minor inaccuracies in the positioning of the attachments were observed in all combinations of thermoforming machines and plastic laminates used to fabricate the templates, mainly in the superior-inferior (Z) dimension. PETG performed better than EVA in the anterior region (p < .05). No association was found between thermoplastification machines and the accuracy of the positioning of the attachments (p > .05). While small misadaptations between the aligners and the attachments were observed, the EVA templates performed better than the PETG templates. The inaccuracy of the attachment positioning and the misadaptation of the aligners to the attachments were slight. The vacuum and pressure thermoplastification machines showed no difference in attachment positioning accuracy. The PETG template was better than the EVA template in the anterior region, but the EVA attachments presented a better adaptation to the aligners than the PETG attachments.

Vacuum Thermoforming of Optically Switchable Liquid Crystalline Elastomer Spherical Actuators.

Liquid crystal elastomer (LCE) actuators are generally limited in shape, size, and quantity by the need for aligning via stretching and fixing via photopolymerizing. A thermoplastic LCE is presented that may be vacuum thermoformed into centimeter-sized hemispheres. The scalable industrial process induces LCE alignment without requiring postfixing. The hemispheres display remarkable properties, actuating with strains around 20% and transitioning from opaque and scattering to highly translucent upon heating: both the physical and optical effects are fully reversible. Simulations reveal the LCE experiences biaxial strains during processing, the magnitude varying as a function of location on the hemisphere: the resulting alignment describing the hemisphere actuation well. The thermoplastic LCE hemispheres may be combined to form complete spheres by simply heating the joint. The hemisphere can also be physically deformed into a ball which can then unfold back into the hemisphere again. By doping the hemispheres with photoswitches, fluorescent or photothermal dyes, devices are formed for light collection and redistribution, addressable water containers that may pour at will, and light-responsive surfing devices. This is the first example of an LCE amenable to high-volume industrial vacuum thermoforming which may lead to intricate 3D-shaped actuators with new functional properties.

A Shear-Stiffening Mouthguard with Excellent Shock Absorption Capability and Remoldability via a Dynamic Dual Network.

Mouthguards are used to reduce injuries and the probability of them to orofacial tissues when impacted during sports. However, the usage of a mouthguard is low due to the discomfort caused by the thickness of the mouthguard. Herein, we have constructed a dynamic dual network to fabricate a shear-stiffening mouthguard with remoldability, which are called remoldable shear-stiffening mouthguards (RSSMs). Based on diboron/oxygen dative bonds, RSSMs show a shear-stiffening effect and excellent shock absorption ability, which can absorb more than 90% of the energy of a blank. Even reducing the thickness to half, RSSMs can reduce approximately 25% of the transmitted force and elongate by about 1.6-fold the buffer time compared to commercial mouthguard materials (Erkoflex and Erkoloc-pro). What is more, owing to the dynamic dual network, RSSMs show good remolding performance with unchanged shear-stiffening behavior and impact resistance, which conforms to the existing vacuum thermoforming mode. In addition, RSSMs exhibit stability in artificial saliva and biocompatibility. In conclusion, this work will broaden the range of mouthguard materials and offer a platform to apply shear-stiffening materials to biomedical applications and soft safeguarding devices.

CARD25: Development of a Minimally Invasive Single Port Pulsatile Ventricular Assist Device

Purpose: Our goal is to develop a compact, single port, pulsatile ventricular assist device (VAD) for total left ventricle (LV) support that only requires a minimally invasive single cannulation from apex to aorta. Methods: Standard diaphragm displacement pumps have 2 valved ports and inlet/outlet cannulas to alternate between blood infusion and withdrawal. By contrast, our compact single port pulsatile VAD consists of a valved single lumen cannula and a valveless single port diaphragm displacement pump. Via a small left thoracotomy, the valved single lumen cannula is inserted from apex to aorta (Fig). Four one-way inlet valves on the valved single lumen cannula wall allow blood withdrawal from LV, and a tri-leaflet outlet valve at the cannula tip allows blood delivery to aorta. The 28 Fr valved single lumen cannula prototype was made as one piece by polyurethane (PU) dip molding with memory alloy reinforcement. The two halves of the valveless single port diaphragm displacement pump prototype housing were made by polycarbonate vacuum thermoforming and assembled with a flexible PU membrane diaphragm in the middle to separate the blood and pneumatic chambers. This pump had a 60 cc stroke volume. A closed mock loop with 37% glycerin was used to mimic the LV-aortic valve-ascending aorta tract. Priming volume and reservoir height were adjusted to maintain 70 mm Hg diastolic aortic pressure and 16 mm Hg preload. Circuit flow and pressure in valved single lumen cannula were recorded. The catheter introducer with pressure transducer on tip was inserted through apex in adult sheep (n=5, 44-52 kg), with pressure wave form guiding tip into ascending aorta. The valved single lumen cannula slid along introducer through apex, crossing aortic valve, with its tip in ascending aorta. The valved single lumen cannula was connected to the single port diaphragm displacement pump. Pumping was increased for a normal cardiac output. The single port pulsatile VAD prototype performance was assessed for 6 hrs with hemodynamics/blood counts recorded. Results: The valved single lumen cannula and single port diaphragm displacement pump prototypes were fabricated as designed. The bench study showed that the single port pulsatile VAD achieved a pumping flow of up to 3.75 L/min. Valve regurgitation was <3%. In the sheep study, the valved single lumen cannula was easily installed within 1 min at first attempt. The single port pulsatile VAD achieved maximal 3.75 L/min pumping flow in a 52 kg sheep. The single port pulsatile VAD had consistent pumping flow through 6 hrs with stable hemodynamics (Table). Hemoglobin and platelet/white blood cell counts were unchanged. No obvious injury or thrombosis in heart or single port pulsatile VAD were observed at necropsy. Conclusions: Our single port pulsatile VAD only requires a single apex cannulation with valved single lumen cannula to achieve reliable LVAD performance, showing great promise for a short to mid-term minimally invasive LVAD.Figure 1. Our single port pulsatile ventricular assist device with a valved single lumen cannula and a valveless single port diaphragm displacement pump. Table 1. - Hemodynamics and Blood Count Results Sheep 1-5 Baseline Pump Run1 hr Pump Run3 hr Pump Run6 hr sABP (mm Hg) 111±15.5 138±19.5 122±16.4 113±16.2 CVP (mm Hg) 11±0.4 11±0.8 11±0.5 11±0.8 CO (L/min) 2.5±0.38 3.8±0.98 3.6±0.66 3.5±0.66 Pump Flow (L/min) 0±0 2.8±0.65* 2.7±0.65* 2.7±0.52* HR (bpm) 154±61.1 104±44.7 105±39.3 127±16 WBC (103/uL) 4.1±0.14 N/A N/A 4.8±2.57 PLT (103/uL) 467±93.3 N/A N/A 380±171 HgB (g/dL) 9.4±0.45 N/A N/A 9.1±0.38 * p<0.05 vs Baseline sABP=systolic arterial pressure, CVP=central venous pressure, CO=cardiac output, HR=heart rate, WBC=white blood cell count, PLT=platelet count, HgB=hemoglobin, and N/A=not applicable.

Vacuum Thermoforming for Packaging Flexible Electronics and Sensors in E-Textiles

Packaging of flexible electronics is essential for e-textile applications to reduce degradation of the performance caused by mechanical stress, environmental effects and to have increased durability. Conformal coatings for packaging have the advantage of reducing rigidity and can be seamlessly integrated into fabrics. Vacuum forming is a technique for packaging electronic devices with thermoplastic films of various thicknesses providing uniform coating. Polyurethane is a widely used thermoplastic material in e-textile and can be easily processed by vacuum forming for packaging. In this paper, a detailed explanation of the working of Formech 450DT vacuum former is discussed for packaging small electronic chip for e-textile application with thermoplastic polyurethane (TPU). Two types of flexible circuits were packaged; a Carbon monoxide gas sensor and a series of resistors on flexible PCB. The packaged CO flexible sensor and series resistors endured 5.3 times and 1.7 times respectively, more bending cycles than unpackaged flexible electronic filament samples. For the washing cycles, the packaged flexible strips with CO sensor and series resistors endured 1.5 times.

Effect of nano-serpentine and nano-La2O3 on the frictional properties of PTFE composites in seawater environment

PurposeThis paper aims to investigate the tribological properties of polytetrafluoroethylene (PTFE) composites modified by nano-serpentine and nano-lanthanum oxide in a seawater environment.Design/methodology/approachIn this paper, seven PTFE composites were prepared by unified design method and vacuum thermoforming method, and their hardness, water absorption and tribological properties were measured under seawater environment. The modification effects and thermal stability of the materials were analyzed by Fourier transform infrared spectroscopy, thermal gravimetry and differential scanning calorimetry. This paper analyzed the wear mechanism of PTFE composites by scanning electron microscopy and energy spectroscopy.FindingsThe results showed that the hardness of the PTFE composites were all improved, but the water absorption was increased with the increase of additives. The modification of nano-serpentine was successful and the thermal stability of PTFE composites was better. The lowest coefficient and minimum wear rate are 0.0267 and 8.67 × 10−5 · mm3 · (N · m)−1 respectively, which is 34.9% and 76% less than the pure PTFE.Originality/valueThe analysis showed that the wear mechanism of PTFE composites was abrasive wear and a small amount of adhesive wear, and when the additive content was appropriate, it easily formed a transfer film on the surface mating parts.

3D Printed Sand Tools for Thermoforming Applications of Carbon Fiber Reinforced Composites-A Perspective.

Tooling, especially for prototyping or small series, may prove to be very costly. Further, prototyping of fiber reinforced thermoplastic shell structures may rely on time-consuming manual efforts. This perspective paper discusses the idea of fabricating tools at reduced time and cost compared to conventional machining-based methods. The targeted tools are manufactured out of sand using the Binder Jetting process. These molds should fulfill the demands regarding flexural and compressive behavior while allowing for vacuum thermoforming of fiber reinforced thermoplastic sheets. The paper discusses the requirements and the challenges and presents a perspective study addressing this innovative idea. The authors present the idea for discussion in the additive manufacturing and FRP producing communities.

Effect of different fabrication methods of occlusal devices on periradicular stress distribution: A photoelastic analysis

Statement of problemInvestigations on the effectiveness of new methods for optimizing the fabrication of oral devices are lacking. PurposeThe purpose of this in vitro study was to evaluate stress distribution with photoelastic analysis in the periradicular area of teeth supporting occlusal devices fabricated by 5 different processes. Material and methodsThe occlusal devices were fabricated by vacuum thermoforming, heat-polymerized acrylic resin, chemical polymerized acrylic resin, 3-dimensional printing, and milling (computer-aided manufacturing). The devices were evaluated regarding initial fit, number of adjustments for passive fit, and stress distribution under 100-N and 400-N loads in the periradicular locations of posterior teeth. ResultsThe 3-dimensional printing device did not require any adjustment for initial adaptation to the photoelastic model and presented a little friction with the model. The heat-polymerized acrylic resin device did not seat initially, requiring more sites of adjustment until passive adaptation. At 100-N and 400-N loads, the use of the computer-aided manufacturing occlusal device resulted in the lowest stresses in periradicular areas (0.744 and 1.583, respectively), and the 3-dimensional printing occlusal device produced the highest stresses with a 400-N load application (2.427). The lowest mean of fringe pattern was observed for the computer-aided manufacturing device, and the highest mean of fringe pattern was observed for the vacuum thermoforming device. ConclusionsThe computer-aided design and computer-aided manufacturing milled occlusal device presented the best initial adaptation and transferred lower stresses to the periradicular areas than the other evaluated devices.

Thermo-visco-hyperelastic behavior of polycarbonate in forming of a complex geometry

Abstract Thermoforming of polymers into intricate geometries entails deliberate control over material deformation to ensure the quality of the final product. Whereas current industrial practices primarily rely on trial and error approaches to identify the proper manufacturing parameters, simulation can expedite the process by offering insight into the interplay of different governing factors. In this paper, we develop a coupled thermal-mechanical finite element model to simulate vacuum thermoforming of a polycarbonate sheet into a finished product. We strive for a fundamental understanding of the interaction between polymer deformation and heat transfer processes that influence the thickness distribution in the final geometry. We employ a nonlinear thermo-visco-hyperelastic model for temperature- and rate-dependent behavior of polycarbonate along with a thermal contact conductivity at the interface of the mold and polymer. Thickness distribution of the simulated part matches well with the measured results of the manufactured part. Through simulation, we further explore certain strategies to redistribute the material in the final product. Our model, which accounts for essential mechanical and thermal aspects of thermoforming processes, provides a means to predict the quality of thermoformed parts in both design and manufacturing phases.

Mechanical and geometric properties of thermoformed and 3D printed clear dental aligners

The aim of this research was to compare compressive mechanical properties and geometric inaccuracies between conventionally manufactured thermoformed Duran clear dental aligners and 3D printed Dental Long Term (LT) resin-based clear aligners using 3D modeling and printing techniques. Impressions of the patient's dentition were scanned and using 3D modeling software, dental models were designed and 3D printed. These printed models then underwent vacuum thermoforming to thermoform a clear Duran thermoplastic sheet of 0.75-mm thickness into clear dental aligners of the same thickness of 0.75mm. For the same dental model, aligners were also designed and 3D printed to 0.75-mm thickness creating biocompatible clear dental aligners using Dental LT resin utilizing a Formlabs 3D printing machine for direct usage by the patients. Five observers calculated teeth height for both types of aligners for evaluation of geometric deviations. Both types of aligners were subjected to compression loading of 1000N to evaluate their load vs displacement behavior. 3D printed cured clear dental aligners were found to be geometrically more accurate with an average relative difference in tooth height of 2.55% in comparison with thermoformed aligners (4.41%). Low standard deviations (0.03-0.09mm) were observed for tooth height measurements taken by all the observers for both types of aligners. 3D printed aligners could resist a maximum load of nearly 662N for a low displacement of 2.93mm; whereas, thermoformed aligners could resist a load on only 105N for 2.93-mm displacement. Thermoformed aligners deformed plastically and irreversibly for large displacements; whereas, 3D printed aligners deformed elastically with reversibility for lower displacements. 3D printed and suitably cured Dental LT resin-based clear dental aligners are suggested to be more suitable for patient use as they are geometrically more accurate; this presents an opportunity to make processing time savings while ensuring an aligner is mechanically stronger and elastic in comparison with the conventionally produced thermoplastic-based thermoformed clear dental aligners.

Bubble assisted vacuum thermoforming: considerations to extend the use of in-situ stereo-DIC measurements to stretching of sagged thermoplastic sheets

In bubble assisted vacuum thermoforming, measuring pressure-induced mechanical strains through the stereo-digital image correlation (stereo-DIC) technique while shaping thermoplastic sheet requires consideration of an appropriate reference state of surface deformations. However, when the stereoscopic measurements can be only performed after the heating step, the correlation problem should be well-posed otherwise the reliability of results is limited. This study focuses on stretching by bubble inflation processes following thermal warpage and sagging of initially flat sheets. For this purpose, an experimental rig is instrumented to heat high impact polystyrene (HIPS) sheets and to perform synchronized pressure and stereoscopic measurements during 1.5 s stretching. A two-step method is introduced to separate mechanical strains which are affected by the uncontrollable change of initial conditions from the global stereo-DIC strains. The first step relies on amplification of damped oscillations at the initiation of the inflation process due to sagging. Out-of-plane displacements confirm the existence of a temperature-dependent characteristic time that marks the transition from the sagged to the strained surface shapes. The second step uses these characteristic times to objectively shift the reference of image-correlation computations. To evaluate the effectiveness of the suggested method, inaccuracy levels of global strains are evaluated at a fixed pressure level under different thermal conditions. It is shown that inaccuracy levels are the highest when stereo-DIC measurements followed warpage and they decrease with amplification of sagging. The developed approach extends the use of in-situ stereo-DIC measurements when changes of initial conditions are uncontrollable and thermal strains cannot be measured.

Dimensional and Geometrical Errors in Vacuum Thermoforming Products: An Approach to Modeling and Optimization by Multiple Response Optimization

Abstract In the vacuum thermoforming process, the product deviations depend on several parameters of the system, which make the analysis, the computational modeling, and the optimization of errors a multi-variable process with conflicting objectives. In this sense, the aim of this work was to study the dimensional and geometrical errors as well as the optimization (minimization) of these errors in one typical vacuum thermoforming product made of polystyrene (PS). In particular, it was intended to predict and minimize errors in a range of ideal tolerances using Multiple Response Optimization (MRO) Models. Thus, through the fractional factorial design (2k-p), initial experimental tests were performed using proposed measurement procedures, and Analysis of Variance being the data analysis is discussed. Following that, the MRO models were implemented which were also validated to represent the sample data. Through this analysis of the results, it can be concluded that the regression models of errors are not linear functions, hence, the developed models are valid for the studied process, and finally that the validation results proved the efficiency of MOR models developed, but these models will not be able to generalize to new situations in a range far from the values studied.

Vacuum Thermoforming Process: An Approach to Modeling and Optimization Using Artificial Neural Networks.

In the vacuum thermoforming process, the group effects of the processing parameters, when related to the minimizing of the product deviations set, have conflicting and non-linear values which make their mathematical modelling complex and multi-objective. Therefore, this work developed models of prediction and optimization using artificial neural networks (ANN), having the processing parameters set as the networks’ inputs and the deviations group as the outputs and, furthermore, an objective function of deviation minimization. For the ANN data, samples were produced in experimental tests of a product standard in polystyrene, through a fractional factorial design (2k-p). Preliminary computational studies were carried out with various ANN structures and configurations with the test data until reaching satisfactory models and, afterwards, multi-criteria optimization models were developed. The validation tests were developed with the models’ predictions and solutions showed that the estimates for them have prediction errors within the limit of values found in the samples produced. Thus, it was demonstrated that, within certain limits, the ANN models are valid to model the vacuum thermoforming process using multiple parameters for the input and objective, by means of reduced data quantity.

Development and clinical evaluation of laser-sintered ankle foot orthoses

ABSTRACTAnkle foot orthoses (AFOs) are traditionally manufactured using vacuum thermoforming as shaping technology. Additive manufacturing has the potential to disruptively change the way these orthopaedic devices are produced. In this study, AFOs are developed which are virtually designed and produced with laser sintering as shaping technology. The mechanical and clinical performances of these laser-sintered AFOs are compared with traditionally manufactured AFO by asking seven patients (both children and adults) to walk with each type of AFO.

Technological support for production of articles of polymers by free thermoforming

The change in temperature field of a sheet, preliminarily heated to a high-elasticity point, during its formation upon production of articles by free vacuum thermoforming is considered.

CAD/CAM silicone auricular prosthesis with thermoformed stiffening insert

Purpose: Epitheses (facial prostheses) for large facial tissue defects manufacturedfrom silicones exhibit unsatisfactory rigidity and its stiffening is required, which createstechnological problems. Moreover, facial epitheses have to be replaced in a relatively shortperiod of use which creates a significant costs, often impossible to realize. The hypothesisof the study was that with use of additive manufacturing is possible to obtain the reusableform for thermoforming of the stiffening insert of auricular prosthesis and the mould whichallows multiple casting of silicone prosthesis with the insert.Design/methodology/approach: Manufacturing of the epithesis consisted of designingand manufacturing. In the first step, the auricular prosthesis and the stiffening insert weredesigned with use of engineering CAD software. In this first computer step, the split form forvacuum thermoforming of the stiffening insert and the split mould for casting of the siliconeear were designed. In the second step, additive printing was used for manufacturing thesplit and reusable model for vacuum thermoforming of the stiffening insert and the splitform of ear. In the third step, stiffening insert was made of thermoformed polyurethane sheetof 0.1 mm thick (Biolon, Dreve), where dental thermoforming machine (Drufosmart, Dreve)was used. In the fourth step, the stiffening insert was located in the mould and the ear wascasting of silicone.Findings: CAD/CAM of epitheses with stiffening insert for large tissues defect/loss wasproposed, where in case of re-producing, it required only thermoforming of insert andcasting silicone with use of the reusable models. Dental technician, in case of damage orloss of a forms, is not much involved in their creation.Research limitations/implications: Bond strength test between stiffening insert vs. softsilicone and manufacturing tolerance of epitheses have not been investigated.Practical implications: Method of casting in a negative form, despite the more timeconsumingwhen comparing with epithesis direct-printing, allows introducing a stiffeninginsert and performing a manual adjustment of margin shape and thickness. Method ofnegative form allows the use of a commercially available medical silicone without the needfor medical tests of a new printed materials.

Mechanical properties of radiation cross linked polyamide 12 after vacuum thermoforming

Generally semi-crystalline thermoplastics have an inferior thermoformability compared to amorphous thermoplastics. This is because of their sharp drop in stiffness and viscosity with crystalline melting. Radiation cross-linking of semi-crystalline thermoplastics offers a solution for this limitation. The thermoformability is essential for processing, but the parts properties like the mechanical ones are important for the application of thermoformed parts. In this article the effects of mold geometry and temperature, forming temperature and film thickness on the mechanical properties of thermoformed cross-linked polyamide 12 (PA12) are investigated. The results show the improvement of the thermoformability of semi-crystalline thermoplastics by cross-linking. Concerning the mechanical properties of the parts, a significant enhancement in stiffness and tensile strength can be obtained, while the ultimate strain at break decreases compared to the smooth film’s properties. Thermal processing conditions, deformations during forming and the degree of cross-linking of the film material have an influence on these effects.

Preparation of polypropylene thermoplastic container via thermoforming process

In this study, plastic containers made of polypropylene (PP) sheets were fabricated via vacuum thermoforming. Thermoforming is a process used in fabricating plastic parts by changing flat thermoplastic sheet to three dimensional shapes. In preparing these thermoplastic containers, the design and fabrication of mould were first done by using Catia V5 software and CNC milling machine, respectively. The thermoforming process was then performed at various temperatures ranging from 160°C until 200°C on the PP sheet to form the container. From the experiment, it can be suggested that the outcomes of final thermoplastic containers are significantly depends on temperature control during thermoforming process and also the vent holes design of the mould.

Flow stress behaviour of ABS (acrylonitrile–butadiene–styrene) at elevated temperature and application to the thermal vacuum forming process

A conventional plastic processing method, vacuum thermal forming, is adopted for manufacturing the large-size rear back of the TV set. The candidate material is the widely used engineering plastic, acrylonitrile–butadiene–styrene (ABS). The basic principle of thermal forming process is to place a heated plastic sheet on a die and clamp with a cover plate whose function is to seal around circumference to establish a vacuum or pressurised compartment. Thus, the softened sheet as being preheated will progress towards and fill up the die underneath when vacuum or pressure is applied. The major problem with thermal forming could be the uneven thickness distribution. To tackle this issue, computer simulation can be an advantageous tool to minimise the number of try-and-error experiments. To run computer simulation for thermal forming, flow behaviour of the ABS is needed as the computer input. Thus, stress–strain relation obtained by tensile tests at various elevated temperatures and strain rate is essential for performing computer simulation work. The constitutive equation based on the widely power law was established. The application was applied to simulate the vacuum thermoforming process of a large-size back cover of television set and the major problem of uneven thickness distribution was successfully simulated with suggested prevention design.

Thermoformable Anhydride–Glycerol Modified Meat and Bone Meal Bioplastics

Meat and bone meal (MBM) can be thermally processed into bioplastics using plasticizers (e.g., glycerol), but such bioplastics have high moisture sensitivity that rapidly degrades their mechanical properties. In this study, resins obtained from controlled reaction of maleic anhydride or phthalic anhydride (PtAH) with glycerol were used in the thermal processing of modified MBM (mod-MBM) bioplastics. Such resins have good chemical interaction with proteisns and have a capacity to cross-link, which results in less mobility and out-diffusion of plasticizers from the bioplastic. The synthesized resins possessed a viscosity of about 1 Pa s at 100 °C, with an onset decomposition temperature of ~140 °C. The bioplastics were prepared by intensively mixing the resin with 60 wt% MBM in a batch compounder at 100 °C prior to thermal compaction into sheets and subsequent vacuum thermoforming. As compared with MBM plasticized with glycerol (gMBM), mod-MBM bioplastics had a nominal tensile strength of 3.7 MPa and a tensile modulus of 580 MPa that were, respectively, 4 times and 10 times greater; their strain to failure of ~1.2 % was 7 times lower. Mod-MBM bioplastics also had significantly improved water resistance such that those modified with PtAH (MBM-PtAH bioplastics) retained structural integrity after being soaked in water for more than 24 h whereas the gMBM bioplastics disintegrated in an hour. Therefore, current results clearly establish that sustainable bioplastics can be developed from biomass with enhanced properties using cost-effective conventional polymer processing routes.