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High Performance polymeric materials are a subject of considerable interest due to their high mechanical performances when combined with their versatility in processing and synthesis. In order to achieve high mechanical properties, scientist focuses on increasing the molecular weight of the polymer produced. However, on increasing the molecular weight, also the viscosity increases due to the large number of entanglements in the non-crystalline region of the semi-crystalline material. The increase in the viscosity leads to challenges in processing the polymeric materials using the conventional techniques. The current state-of-the-art in processing this material is by partial dissolution of a small amount of polymer (~5-10 wt.%) in toxic solvent in order to reduce the entanglements.  A recent development in the processing of the Ultra-High Molecular Weight PolyEthylene (UHMWPE) is achieved by direct synthesis of the polymer having a reduced amount of entanglements. By tailoring the reaction conditions during synthesis and making a meticulous choice of the catalytic system, it is possible to synthesise disentangled-UHMWPE suitable for uniaxial as well as biaxial solid-state processing without using any solvent. The resulting solid-state processed tapes have unprecedented breaking tenacity (>4.0 GPa) and tensile modulus (> 200 Gpa).
The fundamental concept of processing lower entangled high molecular weight polymers is of general nature and can be potentially applied for all the polymeric materials. The current research activity is focusing on testing different catalytic systems for the synthesis of the first solid-state processed biobased fibers for high breaking tenacity and high modulus applications.