MTA-BME Lendület Lightweight Polymer Composites Research Group
Project ID:
LP2020-4/2021
Supported by:
Hungarian Academy of Sciences
Term:
1 September 2020 - 31 August 2025
Supervisor (BME):
Dr. József Gábor Kovács
Participant researchers (BME):
Dr. Tatyana Ageyeva
Dr. András Suplicz
Dr. Dániel Török
Róbert Boros
Dr. Gábor Szebényi
Anna Héri-Szuchács
Dr. Tamás Bárány
Dr. Norbert Krisztián Kovács
Dr. Béla Zink
Dr. Csenge Tóth
Szabolcs Hajagos
Dr. Szabolcs Gábor Krizsma
Richárd Dominik Párizs
Project summary
A new MTA–BME Momentum Research Group for Lightweight Polymer Composites has been established at Budapest University of Technology and Economics, Faculty of Mechanical Engineering, Department of Polymer Engineering. The main aim of the research project is to create a comprehensive technological and modeling background for the novel hybrid TCM (thermoplastic composite material) process. In the project, the researchers will characterize the polymerization kinetics, crystallization kinetics and viscosity of the in situ polymerized thermoplastic for numerical modeling of the T-RTM (Thermoplastic-Resin Transfer Molding) process. Reinforcement structure development will be in focus regarding short and long fibers, such as conventional and 3D printing-based preform technologies for the designable load-bearing structures. Overmolding and overprinting will be further developed as conventional T-RTM technologies are limited in geometries. The project will focus on the numerical modeling and recyclability of these polymers, composites and hybrid composites.
Project results
Section 1
1 September 2020 - 31 August 2021
Section 2
1 September 2021 - 31 August 2022
In the second year, the research group was expanded with additional members and focused on the development of technology and raw materials. The only difficulty was the acquisition of a 3D printer, as it was not possible to obtain equipment on the market that would meet the needs. To solve this, we developed and manufactured our own endless fiber composite printer from the available budget and external support.
The research group successfully applied and thus became part of the RRF-2.3.1-21-2022-00009 – Renewable Energies National Laboratory (2 departments and the research group are members of the application from BME). In the application, the Lendület research group will carry out the practical application of theoretical developments, in which they will create a lightweight hydrogen cell containing only polymer composite main elements by combining T-RTM, injection molding and endless fiber composite 3D printing over the next 3 years.
During the reporting period, two doctoral students completed their doctoral work on the research group's topic and submitted their dissertations.
Section 3
1 September 2022 - 31 August 2023
We achieved our goal of developing a hybrid technology that combines the advantages of injection molding, 3D printing and T-RTM technologies for the production of high-performance, recyclable polymer composite structures. We developed injection molding and T-RTM tools for these complex analyses, which resulted in a doctoral thesis. We implemented the further development of the T-RTM technology by improving the polymerization (conversion). We solved the surface improvement of the T-RTM product with a coating process, which also resulted in a doctoral thesis. We developed an industrial-scale, endless-fiber-reinforced 3D printer, with which we created preforms and inserts for injection molding and T-RTM technologies. We developed an accurate simulation method for calculating the strength of the connection between the components of the injection molding technology. We joined the National Laboratory of Renewable Energies to develop lightweight polymer composite components for energy cells.
Section 4
1 September 2023 - 31 August 2024
In the fourth year of the project, we have made significant progress in the field of in situ polymerization and T-RTM technology. We have developed a polyamide foam core for T-RTM composites, and we have created functionally integrated composite structures that include a combination of a surface layer and a foam core. In addition, we have analyzed the ultrasonic weldability of carbon fiber reinforced polyamide composites manufactured using T-RTM technology using different carbon fiber systems. We have also made significant developments in the field of 3D printing, especially in the printing of multi-component composites. We have created filaments with a high fiber content, continuous reinforcement, and developed and tested in-situ foaming filaments. In addition, we are investigating the technology and the mechanical and morphological properties of the printing of composite sandwich structures, and we are modeling the load-bearing capacity and energy-absorbing composite structures. In the field of injection molding, we developed highly filled polymer composites and analyzed the ultrasonic weldability of carbon fiber reinforced polyamide composites. We refined the control of the injection molding process using reinforcement learning, with particular attention to raw material changes and machine settings. In the field of simulations, we modeled bond strength and examined the effect of injection molding parameters on weld strength in partially crystalline materials. In addition, we applied new computational methods to predict the strength of collision defects. In order to demonstrate the practical utility of the work of the Lendület research group, we sought demonstration tools that would enable most of the technologies, materials, and methods we developed to be put into practice. As a result, the MTA–BME Lendület Lightweight Polymer Composites Research Group joined the National Laboratory for Renewable Energies (RRF-2.3.1-21-2022-
00009) in order to collaborate with o
Section 5
1 September 2024 - 31 August 2025
At the MTA–BME Lendület Lightweight Polymer Composites Research Group, our goal was to develop a hybrid processing technology that combines the advantages of thermoplastic resin transfer molding (T-RTM), injection molding, and 3D printing. With this approach, we have enabled the production of lightweight, high-strength, and fully recyclable composite structures without geometric limitations. We focused on improving the T-RTM process, particularly the in-mold polymerization, enhancing conversion efficiency, and reducing surface defects. As a result, we developed modified mold and coating solutions, which have led to several BSc, TDK, and PhD theses.
To overcome the geometric constraints of T-RTM, we combined it with other processes, producing reinforcing ribs by injection molding or 3D printing, supported by new hybrid mold systems. In the field of 3D printing, we built our own continuous-fiber printer, capable of processing filaments with up to 50,000 individual fibers. The resulting directionally oriented, high-fiber-content preforms significantly increased the load-bearing capacity of hybrid structures.
On the modeling side, we were the first to develop a simulation method that integrates resin flow, fiber infiltration, and in-situ polymerization phenomena. We also made it possible to predict the bonding strength at overmolded interfaces, a capability now implemented in the latest version of Moldex3D, one of the world’s leading injection molding simulation software packages.
We also investigated recycling opportunities, modeling fiber breakage during reprocessing of short-fiber injection-molded composites and quantifying its effect on mechanical performance.
Our results are now being applied in industrial and national collaborations, including the National Laboratory for Renewable Energies, where we are developing lightweight bipolar plates for hydrogen fuel cells using our hybrid technologies. We are also working on lightweight polymer composite gear systems
Project-related publications
Széplaki P.,
Hajagos Sz.,
Krizsma Sz.,
Zink B.,
Suplicz A.: Preparation and analysis of high-performance thermoplastic composites. Polymer Composites,
47, 1860-1871 (2026)
https://doi.org/10.1002/pc.70258 IF=4.7 Q1
Kovács J. G.: Advanced lightweight injection-molded polymer composites: Recycling, hybrid manufacturing, and integration of industry 4.0. in '6.International Polymeric Composites Symposium and Workshops İzmir, Turkey. 2025.10.02-2025.10.04,3 (2025)
Krizsma Sz. G.,
Suplicz A.: Comparative study of additively manufactured, state-of-the-art photopolymers and their applicability in prototype mould making. International Journal of Advanced Manufacturing Technology,
139, 6187-6200 (2025)
https://doi.org/10.1007/s00170-025-16286-0 IF=3.1 Q2
Szederkényi B.,
Kovács N. K.,
Czigány T.: A comprehensive review of fiber-reinforced topology optimization for advanced polymer composites produced by automated manufacturing. Advanced Industrial and Engineering Polymer Research,
8, 113-131 (2025)
10.1016/j.aiepr.2024.05.002 IF=12 Q1
Vas L. M.,
Tóth Cs.,
Petrény R.,
Virág Á. D.: Stochastic modeling framework for polymer bonding based on classical physics and chemical bonding model. Applied Physics A: Materials Science and Processing,
131, 892/1-892/1-19 (2025)
https://doi.org/10.1007/s00339-025-08971-4 IF=2.8 Q2
Hajagos Sz.,
Kovács J. G.: Polymer-based bipolar plates for fuel cells: design, simulation, and manufacturing. Periodica Polytechnica-Mechanical Engineering,
69, 40-45 (2025)
10.3311/PPme.38589 IF=1 Q4
Krizsma Sz. G.,
Suplicz A.,
Gere D.: Customised production of injection moulded parts from recycled materials using rapid tooling approach and coupled injection moulding-thermal and mechanical simulation. Results in Engineering,
26, 105272/1-105272/15 (2025)
https://doi.org/10.1016/j.rineng.2025.105272 IF=7.9 D1
Hajagos Sz., Zink B., Kovács J. G.: Elektromos vezető monokompozitok vizsgálata. Polimerek, 11, 121-128 (2025)
Hajagos Sz.,
Kovács J., G.,
Suplicz A.,
Széplaki P.,
Zink B.: An experimental and theoretical study on the electrical conductivity of polymer composites. Journal of Materials Research and Technology,
39, 6300-6309 (2025)
https://doi.org/10.1016/j.jmrt.2025.10.217 IF=6.6 Q1
Krizsma Sz.,
Mészáros L.,
Kovács N. K.,
Suplicz A.: Expanding the applicability of material jetting–printed photopolymer prototype injection moulds by gamma irradiation post-treatment. Journal of Manufacturing Processes,
134, 135-145 (2025)
https://doi.org/10.1016/j.jmapro.2024.12.037 IF=6.8 Q1
Virág Á. D.,
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Kohári A.,
Tóth Cs.: Substitution of carbon black with wood biochar in natural rubber composites: A study on reinforcement and sustainability. Results in Engineering,
28, 107843/1-107843/13 (2025)
https://doi.org/10.1016/j.rineng.2025.107843 IF=7.9 D1
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Kovács J. G.: Real‐time product weight estimation based on internal pressure monitoring in injection molding. Polymer Engineering and Science,
65, 1693-1701 (2025)
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Virág Á. D.: A modifed Halpin–Tsai model for the tensile properties of short fber‑reinforced 3D‑printed composites using fber content‑dependent orientation correction factor. International Journal of Advanced Manufacturing Technology,
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Hajagos Sz., Zink B., Kovács J. G.: Optimisation of polymer-based bipolar plates using numerical calculation. in '3rd IPPT_TWINN Conference: Metal replacement and lightweight polymer composites Slovenj Gradec, Szlovénia. 2025.06.04-2025.06.05., (2025)
Suplicz A., Széplaki P.: Properties of carbon fiber-reinforced lightweight polyamide composites produced by in situ polymerization. in '3rd IPPT_TWINN Conference: Metal replacement and lightweight polymer composites Slovenj Gradec. 2025.06.04-2025.06.05.,8 (2025)
Tóth Cs.,
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Kovács N. K.,
Bárány T.: Additive manufacturing of thermoset elastomers: A review of emerging technologies. Engineering Science and Technology, an International Journal,
69, 102143/1-102143/23 (2025)
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Zink B.,
Szuchács A.,
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Kovács J. G.: Modeling the effect of scale deposition on heat transfer in injection molding. Scientific Reports,
15, 1-9 (2025)
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Kovács J. G.: Impact of fiber fragmentation on mechanical performance and environmental footprint of recycled glass fiber-reinforced polyamide composites. Journal of Cleaner Production,
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10.1016/j.jclepro.2025.145678 IF=10 D1
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Bárány T.: Influence of viscosity ratio on the mechanical, morphological, and rheological properties of thermoplastic dynamic vulcanizates from devulcanized tire rubber and polypropylene. Macromolecular Materials and Engineering,
310, e00224/1-e00224/12 (2025)
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Széplaki P., Suplicz A.: Development of a coating process for continuous fiber reinforced thermoplastic composites manufactured with T-RTM technology. in '3rd IPPT_TWINN Conference: Metal replacement and lightweight polymer composites Slovenj Gradec. 2025.06.04-2025.06.05.,21 (2025)
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Horváth Sz.,
Kovács J. G.: Determination of wall thickness effect of in-mold viscosity measurement under non-adiabatic, non-isothermal flow conditions. Express Polymer Letters,
19, 246-257 (2025)
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301, 112513/1-112513/11 (2025)
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Petrény R.: Optimizing the injection molding process for thermally and electrically conductive, carbon fiber and carbon nanotube-reinforced poly(lactic acid) hybrid composites with enhanced mechanical properties. Journal of Applied Polymer Science,
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68, 78-84 (2024)
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Széplaki P., Suplicz A.: Poliamid 6 mátrixú kompozit szendvicsszerkezetek gyárthatósága T-RTM technológiával. Polimerek, 10, 226-232 (2024)
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Kovács J. G.: Calculation of the bonding strength of semi-crystalline polymers during overmolding. Polymer Testing,
139, 1-6 (2024)
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24, 103505/1-103505/11 (2024)
https://doi.org/10.1016/j.rineng.2024.103505 IF=7.9 D1
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Krizsma Sz.,
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Suplicz A.: Coupled injection moulding simulation–thermal and mechanical simulation method to analyse the operational behaviour of additively manufactured polymeric injection moulds. Results in Engineering,
23, 102558/1-102558/16 (2024)
https://doi.org/10.1016/j.rineng.2024.102558 IF=7.9 D1
Marton G. Zs., Szebényi G.: The effect of pattern width on the properties and behavior of interfacially engineered composites with designed failure. in 'ECCM21 – 21st European Conference on Composite Materials Nantes, Franciaország. 2024.07.02-2024.07.05.,1438-1443 (2024)
Tóth Cs.,
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Kovács N. K.: Prediction and analysis of flexural stiffness for 3D-printed continuous fiber–reinforced composites with different matrix fill ratios and layer orders. Polymer Testing,
135, 108459/1-108459/11 (2024)
https://doi.org/10.1016/j.polymertesting.2024.108459 IF=6 D1
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16, 00455/1-00455/19 (2024)
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Tóth Cs.,
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22, 102075/1-102075/8 (2024)
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Kovács N. K.: The role of the fiber–matrix interface in the tensile properties of short fiber–reinforced 3D-printed polylactic acid composites. Polymer Composites,
45, 13589-13602 (2024)
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Molnár K.: Tailoring the mechanical and rheological properties of poly(lactic acid) by sterilizing UV-C irradiation. International Journal of Biological Macromolecules,
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Kohári A., Bárány T.: Termoplasztikus poliuretán alapú elasztomer fejlesztése újrahasznosított gumiőrlet társításával. Műanyag- és Gumiipari Évkönyv, 21, 94-98 (2023)
Kiss B., Párizs R. D., Tóth Cs., Török D., Kovács N. K.: Anyagextrúzió alapú additív gyártástechnológiával készült termékek anizotróp viselkedésének elemzése. Polimerek, 5, 155-160 (2023)
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42, 43/1-43/15 (2023)
10.1007/s10921-023-00957-7 IF=2.6 Q2
Kara Y.,
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Boros R.,
Molnár K.: A novel method and printhead for 3D printing combined nano-/microfiber solid structures. Additive Manufacturing,
61, 103315/1-103315/13 (2023)
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Varga L. J., Bárány T.: Development challenge for synthetic polymer fibers and tapes: improving toughness.
Szuchács A.,
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Kovács J. G.: Modeling and measuring the bonding strength of overmolded polymer parts. Polymer Testing,
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10.1016/j.polymertesting.2023.108133 IF=5 D1
Kovács J. G.: The future of polymer science is Artificial Intelligence: Opportunities and challenges.
Párizs R. D.,
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Ageyeva T.,
Kovács J. G.: Multiple in-mold sensors for quality and process control in injection molding. Sensors,
23, 1735/1-1735/18 (2023)
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67, 151-160 (2023)
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Krizsma Sz.,
Suplicz A.: Analysis of the applicability and state monitoring of material extrusion–printed acrylonitrile butadiene styrene injection mould inserts with different infill levels. Materials Today Communications,
35, 106294/1-106294/12 (2023)
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Bárány T.: Polypropylene blends for highly drawn tapes with improved toughness. ACS Omega,
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Suplicz A.: The degradation during recycling of polyamide 6 produced by anionic ring‑opening polymerization of ε‑caprolactam. Scientific Reports,
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Krizsma Sz., Suplicz A.: Prototípus fröccsöntő szerszámok üzem közbeni állapotfelügyelete és termékminőség vizsgálata. in 'XXXI. Nemzetközi Gépészeti Konferencia Temesvár, Románia. 2023.04.17-2023.04.30.,323-328 (2023)
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Krizsma Sz. G.,
Suplicz A.: Monitoring and modelling the deformation of an aluminium prototype mould insert under different injection moulding and clamping conditions. Results in Engineering,
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Török D.,
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Kovács J. G.: Laser powder bed fusion and casting for an advanced hybrid prototype mold. Journal of Manufacturing Processes,
81, 748-758 (2022)
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Szebényi G.: High-performance composites and medical applications of polymers - the sunny sides of the polymer industry. Express Polymer Letters,
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22, 2704/1-2704/16 (2022)
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Tóth Cs.,
Kovács N. K.: Comparison of the accuracy of analytical models for basalt fiber–reinforced poly(lactic acid) composites prepared by injection molding and fused filament fabrication. International Journal of Advanced Manufacturing Technology,
121, 3999–4010 (2022)
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Krizsma Sz. G.,
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84, 1298-1309 (2022)
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Szuchács A., Kovács J. G.: Termoplasztikus polimerek molekulahosszának hatása a kialakuló kötésszilárdság számítási módszerére. Polimerek, 8, 58-64 (2022)
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32, 103936/1-103936/8 (2022)
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Suplicz A.: The effect of the titanium dioxide nanoparticles on the morphology and degradation of polyamide 6 prepared by anionic ring-opening polymerization. Polymer Engineering and Science,
62, 2079-2088 (2022)
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106, 107446/1-107446/11 (2022)
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Kovács J. G.: Developing a method for evaluating color changeover in a hot-runner multi-cavity injection mold. Polymer Testing,
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10.1016/j.polymertesting.2022.107759 IF=5.1 D1
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66, 350-360 (2022)
10.3311/PPme.21048 IF=1.3
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Kovács J. G.: Pressure‐dependent heat transfer coefficient measurement for thermoplastic melts. Polymer Engineering and Science,
62, 1137-1146 (2022)
10.1002/pen.25912 IF=3.2 Q2
Semperger O. V., Pomlényi P., Suplicz A.: Felület-bevonatolási eljárás T-RTM technológiához. Polimerek, 7, 186-192 (2021)
Krizsma Sz. G.,
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Suplicz A.: In-situ monitoring of deformation in rapid prototyped injection molds. Additive Manufacturing,
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