Control and design problems in material processing—how can process systems engineers contribute to material processing?

‘Process control and systems engineering’ is not just a subject of study for controlling and designing ‘a plant’ and/or ‘a unit operation’. It also deals with any control and design problems related to physical and chemical phenomena occurring in short time-scale and at nano, meso as well as micro-scale levels. In materials processing, controlling the material structure is of primary importance for realizing high material performance and functions. The phenomena determining the material structure often involve phase separation and/or occur on the surface of the materials, at small level and in short time-scale. To control these phenomena, the current feedback design schemes, where controlled variables are measured by ‘externally equipped sensors’ and fed back to a ‘externally designed controller’, are no longer effective due to the shortness of time and smallness of spatial scales of the objects. Making reference to two novel polymer-processing processes, a micro-cellular polymeric foaming process and surface coating injection-molding process, we discuss how process control and process systems engineers can contribute to controlling the structure of materials.