9702443 Nied This research project is to develop design principles for integrating design and manufacture of load bearing structural components fabricated from thermoplastic materials. The mechanism for achieving this plan is the design and forming of advanced structural parts from thermoplastic materials using blow molding and thermoforming processes. The outcomes of this study could significantly improve the linkage between processing mechanics, material behavior, and structural performance of the load bearing applications. The research activities have balanced theory and experiments to adequately characterize the process physics, developing process simulation models, and the necessary testing techniques to measure the relevant polymer materials properties that are uniquely required for thermoforming and blow molding process simulation. The research activities will be balanced by an education plan to improve quality of graduate and undergraduate education at Lehigh University.