Alternating (A-B-A) n polymer films with individual layer thicknesses in the 3-25 μm range were produced using a robust layer multiplying coextrusion process. Such a film with layers of a poly-(propylene-graft-maleic anhydride) (PPgMA) alternating with layers of PPgMA containing a phosphate glass (Pglass) upon biaxial orientation exhibited percolation of high barrier filler platelets resulting in reduction in gas permeation by two to 3 orders of magnitude. This unprecedented reduction in oxygen permeability was attributed to the high volume fraction of highly aligned Pglass platelets in the polymer matrix resembling a brick wall microstructure. Biaxially oriented films with 20 vol % Pglass content exhibited a microstructure resembling alternating organic and inorganic layers, a close replica of natural biocomposites. Structural models for permeability indicated that enhanced barrier resulted from increased tortuosity of the diffusion pathway provided by the aligned high aspect ratio platelets. Aspect ratios ranging from 40 to 175 were calculated by fitting the experimental data to diffusion models. Mechanical tests revealed that the presence of Pglass platelets increased the modulus of the multilayer composites by as much as 2Â, without any considerable loss in ductility. The improvement in mechanical properties was ascribed to the high aspect ratio of the oriented Pglass platelets. Biaxially oriented films conditioned at high relative humidity (97% RH) maintained their high oxygen barrier properties. With an optical transparency between 60 and 85%, and good flexibility, these films stood out as good candidates for a variety of packaging applications.

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Immobilization casts are used to reduce patient movement during the radiotherapy of head and neck and brain malignancies. Polyethylene-based casts are produced by first taking a Plaster of Paris 'negative' impression of the patient. A 'positive' mould is then made, which is used to vacuum form an immobilization cast. Taking the 'negative' cast can be messy, stressful for patients and labour intensive. Recently, lightweight hand-held laser surface scanners have become available. These allow an accurate 3-D representation of objects to be generated non-invasively. This technology has now been applied to the production of casts for radiotherapy. Each patient's face and head is digitized using the Polhemus FastSCAN (Polhemus, Colchester, VT, USA) scanner. The electronic data are transferred to a computer numerical controlled mill, where a positive impression is machined. The feasibility of the process was examined, the labour required and radiation therapists' satisfaction with aspects of the produced masks assessed. The scanner-based method of mask production was found to be simple, accurate and non-invasive. There was a reduction in radiation therapist labour required. Masks produced with the scanner-based method were reported to result in improved mask fitting, daily reproducibility, patient immobilization and patient comfort.

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