Plasticized and reinforced poly(methyl methacrylate) obtained by a dissolution-dispersion process for single point incremental forming: Enhanced formability towards the fabrication of cranial implants

A plasticized and reinforced material made of poly(methyl methacrylate), PMMA, was developed via an effective dissolution-dispersion method to enhance its formability in Single Point Incremental Forming process (SPIF). Different contents of triacetine (plasticizer), and Cloisite 30B nanoclay (C-30B) used as reinforcement, were added to PMMA based on a factorial design of experiments with center points. A synergistic effect between triacetine and C-30B was evidenced during the SPIF processing of the PMMA composite material. The addition of triacetine produced the relaxation and mobility of polymer chains, while C-30B improved the mechanical properties without affecting the formability. The transfer of stresses during SPIF of cone-shaped parts was enhanced due to a mechanical interlocking effect between the nanoclay and the PMMA chains, in addition to the formation of intercalated nanostructures within the clay galleries. The potential application of these PMMA-based composite materials for manufacturing cranial implants is addressed in this work as well. [Display omitted] •A dissolution-dispersion process to plasticize and reinforce PMMA was proposed.•The PMMA, of brittle nature, was able to be formed by SPIF at room temperature.•Polymer chains penetrated into nanoclay layers forming intercalated nanostructures.•A mechanical interlocking effect was shown between nanoclay and polymer chains.•The developed composite showed a potential SPIF manufacture use in cranial implants.