João M. Maia

Case Western Reserve University

Applied Mathematician

Fellow, Elected 2025

Dr. Maia has made significant contributions to practical polymer processing and in-line polymer characterization. He created a new static mixer for single- and twin-screw extruders to produce very fine morphologies, which have been implemented commercially. He has also developed new split and combine flow dies and processing additives to greatly expand the range of rheological mismatch of multiple polymers that can be extruded into useful and unique two- and three-dimensional structures. This enables the manufacture of a myriad useful structured polymer composites for mechanical, thermal, electronic, packaging and biomedical applications.

Dr. Maia has also developed in-line tools for monitoring polymer processing and characterization in screw extruders. These include capillary and rotational rheometers and slit dies for slit rheometry and rheo-optical analysis. These tools provide unique access to the polymer and the extruder for process and quality control. With the growth of AI and machine learning, the data from these tools will also provide insights for processing-property relationships, process adjustment for feedstock variations, and for scheduling maintenance. Off line, he has developed a novel dual controlled-stress/rate rheometer limited in extension only by sample rupture that allows characterization of the creep behavior in extension, constant-strain rupture studies, and constant-stress to develop relationships with the onset of processing defects. As of 2025, this rheometer allows the highest reported Hencky strain in homogeneous conditions of 8.14 on a SBR melt.

Through these scientific endeavors, João has published 170 journal papers and seven book chapters, has been granted 14 patents, and has advised more 30 PhD and 23 MS students and 17 postdocs. Joao has been recognized for his contributions to rheology by the 2010 Annual Award of the British Society of Rheology and the 2011 Morand Lambla Award of the Polymer Processing Society.