Process and Material Parameter Optimisation of Rotomoulded Polymer Foams

Polymer foams are essential for the manufacture of low cost, lightweight, buoyant structures typical of offshore energy generation devices. Careful balancing of material and processing conditions is essential to achieving a mechanically optimal cellular structure. To date, a convenient method for optimising rotationally moulded polymer foams has not been demonstrated. An offline experimental method was developed, and a preliminary study conducted, analysing the influence of processing and material parameters, such as polymer particle size or chemical blowing agent (CBA) concentration, on polymer cellular structures. The density of each sample was analysed, and image analysis software used to compare the amount of cell deterioration in each specimen cross-section. The method was found to be capable of indicating appropriate levels of each variable, offering a quicker route to foam optimality based on minimising density and preventing cell deterioration.