Enhancing Student Understanding of Polymer Processing through a Multi-module Laboratory Course: Bridging Simulation and Practice

Polymer processing and characterization are core components of materials science and chemical engineering curricula, yet undergraduate students often encounter these topics only through theoretical instruction, computer-based simulations, and isolated polymer-related experiments. This experience limits their ability to fully appreciate the relationships between polymer structure, processing conditions, and material properties. To address this gap, a multimodule laboratory course was developed that introduces students to polymer synthesis, thermal behavior, and mechanical testing through three interconnected experiments: (i) gel time determination of reacting thermosetting resins, (ii) glass transition temperature analysis of common polymers using differential scanning calorimetry, and (iii) specimen fabrication via injection molding followed by mechanical property evaluation using a universal testing machine. Each module was designed to complement students’ prior theoretical knowledge while emphasizing practical laboratory techniques and data interpretation. Student engagement with these modules fostered deeper comprehension of polymer chemistry and processing, while also strengthening critical skills such as experimental design, data analysis, and technical reporting. This work demonstrates an effective framework for bridging the gap between simulation-based learning and experimental practice, thereby enhancing undergraduate education in polymer science and engineering.