Project Description
McNeall Plastics manufactures using anionic ring-opening polymerization (AROP) of caprolactam.
While this manufacturing process has been used within the business for many years, much of the detailed scientific and process knowledge surrounding the reaction has historically been based on practical experience, established operating procedures and external supplier expertise rather than a comprehensive scientific model of the reaction.
Over time, a significant amount of this institutional knowledge has been lost. This has been compounded by the closure of a long-term raw material supplier that previously provided both key reaction components and technical support.
As a result, there is a need to develop a deeper, independently held understanding of the polymerisation process and the interaction between its key parameters.
The proposed research project will characterise the AROP reaction used in our cast nylon manufacturing process.
The work will investigate the influence and interaction of key reaction variables, including catalyst and co-catalyst systems, additive chemistry, concentrations, temperature, reaction kinetics and their influence on resulting polymer properties.
A key objective is to use experimental data and scientific literature to develop a mathematical or mechanistic model of the reaction.
This model would help identify relationships between process inputs, reaction behaviour and final material properties, providing a more rigorous basis for process understanding.
This understanding will then support the systematic evaluation and qualification of alternative additives, catalysts, co-catalysts and raw material suppliers.
Ultimately, the project aims to convert historically experience-based process knowledge into documented, measurable and transferable scientific knowledge that can support future R&D and manufacturing decisions.
Industry: Technology
Study area: Engineering
Partner: McNeall Plastics
Suburb: Unanderra
Why:
McNeall Plastics is an Australian-owned engineering plastics manufacturer based in NSW, with over 50 years of experience.
We manufacture AustLon - monomer cast nylon and machine components from a range of engineering plastics.
Our work includes bearings, bushes, rollers, gears, rope sheaves, wear plates and custom components for mining, materials handling, manufacturing and general engineering.
AustLon is cast locally using gravity and centrifugal casting processes. We can produce large and complex cast nylon components up to 3m x 3m x 2m, as well as machining services to customer drawings.
We also assist with material selection, component design, machining requirements while considering factors such as load, temperature, and chemical exposure.
Paid
Yes
Selection Criteria
Skills wish list:
- Polymer chemistry
- Technical problem solving, documentation and strong communication skills
- Design of experiments
- Reaction kinetics
- Mechanical design
Research Outcomes
The primary outcome of the project will be a deeper, documented scientific understanding of the AROP process used in the manufacture of cast nylon.
The project is expected to identify the critical reaction and process parameters, quantify their influence where practicable, and establish relationships between raw material inputs, processing conditions, reaction behaviour and resulting polymer properties.
A key deliverable will be the development of a model of the reaction. The model should provide a framework for interpreting experimental results, understanding interactions between reaction variables and, where supported by the data, predicting the effect of changes to reaction conditions or chemistry.
The project should also establish a repeatable experimental and qualification methodology for assessing alternative catalysts, co-catalysts and additives. This will allow potential new raw materials and suppliers to be evaluated against defined technical criteria rather than relying primarily on historical knowledge or supplier-specific technical support.
Additional outcomes will include identification of appropriate operating ranges for key reaction parameters, improved documentation of the underlying reaction chemistry and the creation of a technical knowledge base that can be retained and developed internally.
Additionally, design, build and validate practical test rigs and methodologies for evaluating application-relevant properties of AustLon and experimental formulations. Initial testing may include linear sliding wear and bearing/bushing wear. An objective to establish repeatable testing methods that allow changes in reaction chemistry, additives and processing conditions to be correlated with measurable material performance.
Collectively, these outcomes should provide McNeall Plastics with a stronger scientific foundation for future process development, raw material qualification, troubleshooting and R&D, while reducing reliance on undocumented institutional knowledge and individual suppliers.
Duration
3 months
Application closing date
25 September 2026
Contact information
Georgia Watson