Abstract: A closed loop recycling process of manufacturing a foam part includes dispersing a filler material recycled from an additive manufacturing (AM) process in at least one foam reactant and pouring or injecting the at least one foam reactant with the filler material into a mold and forming the foam part. The foam part has a foam matrix with between 2.5 wt. % and 30 wt. % of the filler material. The filler material can be a recycled powder from a selective laser sintering process that is not graded (i.e., sized) before being dispersed in the at least one foam reactant. For example, the recycled powder can be a recycled polyamide 12 (rPA12) powder with an average particle diameter of less than 100 micrometers. Also, the least one foam reactant can be a polyol reactant and an isocyanate reactant such that a polyurethane foam matrix with recycled rPA12 filler material is formed.

Abstract: A closed loop recycling process of manufacturing a foam part includes dispersing a filler material recycled from an additive manufacturing (AM) process in at least one foam reactant and pouring or injecting the at least one foam reactant with the filler material into a mold and forming the foam part. The foam part has a foam matrix with between 2.5 wt. % and 30 wt. % of the filler material. The filler material can be a recycled powder from a selective laser sintering process that is not graded (i.e., sized) before being dispersed in the at least one foam reactant. For example, the recycled powder can be a recycled polyamide 12 (rPA12) powder with an average particle diameter of less than 100 micrometers. Also, the least one foam reactant can be a polyol reactant and an isocyanate reactant such that a polyurethane foam matrix with recycled rPA12 filler material is formed.

Abstract: A cellular material. The cellular material can be the reaction product of a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol; and an isocyanate.

Abstract: A cellular material. The cellular material can be the reaction product of a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol; and an isocyanate.

Abstract: A cellular material. The cellular material can be the reaction product of a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol; and an isocyanate.

Abstract: The present invention, in at least certain aspects, provides a cellular material, a method of making cellular material, and a composition for making the cellular material. The cellular material comprises the reaction product of soy-based polyol, petro-based blowing agent, cross-linking agent, a combination of silicone surfactants and isocyanate.

Abstract: The present invention discloses a method for dispersing and exfoliating fillers in a thermoplastic polymer by sonicating a mixture of the thermoplastic polymer and the filler. The method of the present invention is particularly useful in dispersing layered silicate clays in thermoplastic polymers. A reinforced composite comprising a filler dispersed in a thermoplastic polymer is also disclosed. In another variation, the method of the invention is incorporated into conventional plastic extruder and injection molding equipment.