Applied Chemical Engineering

Surface metamorphosis techniques for sustainable polymers: Optimizing material performance and environmental impact

Raja Subramani

Centre for Sustainable Materials and Surface, Metamorphosis, Chennai Institute of Technology Chennai, India

Rusho Maher Ali

Lockheed Martin Engineering Management, University of Colorado, Boulder, Colorado, 80308, United States

Raviteja Surakasi

Department of Mechanical Engineering, Lendi Institute of Engineering and Technology, Jonnada, Vizianagaram Andhra Pradesh, 535005, India

D. Raga Sudha

Department of Chemistry, Basic Sciences and Humanities, Vignan Institute of Information and Technology, Visakhapatnam, Andhra Pradesh, 530049, India

S. Karthick

Department of Mechanical Engineering, K. S. Rangasamy College of Technology, Tiruchengode, Tamilnadu, 637215, India

Karthikeyan S.

Department of Mechanical Engineering, Erode Sengunthar Engineering College, Erode, Tamilnadu, 638057, India

N. Nagabhooshanam

Department of Mechanical Engineering, Aditya University, Surampalem,533437, India; Department of Mechanical Engineering, Institute of Engineering and Technology, GLA University Mathura, 281406, India

Jeyanthi Subramanian

School of Mechanical Engineering, Vellore Institute of Technology, Chennai, Tamilnadu, 600127, India

Vinoth Kumar Selvaraj

School of Mechanical Engineering, Vellore Institute of Technology, Chennai, Tamilnadu, 600127, India

DOI: https://doi.org/10.59429/ace.v7i3.5528

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Abstract

The transition to sustainable polymers is crucial for reducing the environmental footprint of additive manufacturing, particularly in fused deposition modeling (FDM). This study investigates surface metamorphosis techniques—methods to modify polymer surfaces at micro and nanoscale levels to enhance performance and minimize environmental impact. We explore plasma treatment, chemical etching, and laser texturing on biodegradable and recycled polymers, assessing their effects on surface properties, such as adhesion, roughness, and chemical resistance. Our results demonstrate significant enhancements in mechanical properties. For example, PLA’s tensile strength increased from 55.3 MPa (untreated) to 63.8 MPa (plasma treated), and its elongation improved from 4.2% to 5.1%. PHA showed a similar trend, with tensile strength rising from 45.1 MPa to 52.6 MPa, and elongation increasing from 5.6% to 6.4%. rPET and rPP also exhibited improvements, indicating the effectiveness of these surface treatments. Employing a multi-criteria decision-making approach, we assess and prioritize these techniques based on their mechanical enhancements and sustainability profiles. While this study presents hypothetical results, it establishes a comprehensive framework for optimizing surface metamorphosis processes, guiding future experimental research. Our findings suggest that tailored surface modifications can significantly improve the performance and environmental sustainability of polymers in FDM, offering pathways for integrating eco-friendly materials into advanced manufacturing. This work contributes to the development of green manufacturing technologies by highlighting surface metamorphosis as a key strategy for achieving high-performance and sustainable materials.

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