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This article presents the first use of shape forming elements (SFEs) to produce architected composites from multiple materials in an extrusion process. Each SFE contains a matrix of flow channels connecting input and output ports, where materials are routed between corresponding ports. The mathematical operations of rotation and shifting are described, and design automation is explored using Bayesian optimization and genetic algorithms to select fifty or more parameters for minimizing two objective functions. The first objective aims to match a target cross-section by minimizing the pixel-by-pixel error, which is weighted with the structural similarity index (SSIM). The second objective seeks to maximize information content by minimizing the SSIM relative to a white image. Satisfactory designs are achieved with better objective function values observed in rectangular rather than square flow channels. Validation extrusion of modeling clay demonstrates that while SFEs impose complex material transformations, they do not achieve the material distributions predicted by the digital model. Using the SSIM for results comparison, initial stages yielded SSIM values near 0.8 between design and simulation, indicating a good initial match. However, the control of material processing tended to decline with successive SFE processing with the SSIM of the extruded output dropping to 0.023 relative to the design intent. Flow simulations more closely replicated the observed structures with SSIM values around 0.4 but also failed to predict the intended cross-sections. The evaluation highlights the need for advanced modeling techniques to enhance the predictive accuracy and functionality of SFEs for biomedical, energy storage, and structural applications. 

The halogen-free synthesis of oligosilazanes has been observed upon dehydrocoupling silanes with ammonia at 25 °C using [(2,6-iPr2PhBDI)Mn(µ-H)]2. Extending this methodology to polymethyl-hydrosiloxanes afforded thermally robust polysiloxazane solids, and the dehydrocoupling of 1,3,5,7-tetramethylcyclotetrasiloxane with ammonia afforded a polysiloxazane having a weight-average molecular weight of 4300 g/mol. A representative oligosilazane has been applied to a copper surface and found to afford a 20 μm thick coating that resists corrosion after 24 h under water. Addition of ammonia to [(2,6-iPr2PhBDI)Mn(µ-H)]2 allowed for characterization of the catalyst resting state, [(2,6-iPr2PhBDI)Mn(µ-NH2)]2, which has been found to mediate Si‒N dehydrocoupling. 

Abstract This study aims to establish a systematic approach for characterizing recycled polyolefins of unknown composition, with a specific focus on predicting their performance in film extrusion. We explore various characterization techniques, including differential scanning calorimetry (DSC), Fourier‐transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and rheometry to assess their effectiveness in identifying the polyethylene (PE) fractions within polypropylene (PP) recyclates. By integrating experimental data with modeling techniques, we aim to provide insights into the predictive capabilities of these techniques in determining processing behaviors. The research highlights the superior fidelity of DSC in predicting the relative fraction and type of PE in a PP recyclate. FTIR is also identified as a high‐fidelity approach, albeit requiring application‐specific calibration. TGA, capillary, and oscillatory rheometry are recognized for their ability to distinguish between grades of recycled polyolefins but provide aggregate behaviors rather than detailed constituent information. 3D flow simulation of the cast film extrusion investigated the effect of the viscosity characterization method, non‐isothermal assumption, and process settings but could not fully replicate the observed variations in the cast film processing of two industrial polyolefins with similar melt flow rates and viscosity behaviors. This underscores the practical challenge of predicting processing issues prior to actual processing, necessitating reliance on reliable instrumentation suites and human expertise for diagnosing and remedying variations. HighlightsTwo industrial recycled polypropylene materials having similar melt flow rates exhibit drastically different cast film processing behaviors.DSC and FTIR provide reasonable approaches for identifying constituent materials.Modeling of the melt viscosities characterized by capillary and parallel plate rheology suggests that viscosity variations relative to the power‐law behavior assumed in the coat hanger die design is a predominant driver of cast film instabilities. 

Highly pathogenic avian influenza (HPAI) viruses cross species barriers and have the potential to cause pandemics. In North America, HPAI A(H5N1) viruses related to the goose/Guangdong 2.3.4.4b hemagglutinin phylogenetic clade have infected wild birds, poultry, and mammals. Our genomic analysis and epidemiological investigation showed that a reassortment event in wild bird populations preceded a single wild bird–to-cattle transmission episode. The movement of asymptomatic or presymptomatic cattle has likely played a role in the spread of HPAI within the United States dairy herd. Some molecular markers that may lead to changes in transmission efficiency and phenotype were detected at low frequencies. Continued transmission of H5N1 HPAI within dairy cattle increases the risk for infection and subsequent spread of the virus to human populations.