Extending Cellulose-Based Polymers Application in Additive Manufacturing Technology: A Review of Recent Approaches

Mohan, Denesh; Teong, Zee Khai; Bakir, Afifah Nabilah; Sajab, Mohd Shaiful; Kaco, Hatika

doi:10.3390/polym12091876

Cited by 59 publications

(41 citation statements)

References 175 publications

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“…Nanocellulosic materials are, indeed, suitable for 3D printing, and have shown great potential in biomedical applications and scaffolding, where the intended use is in the wet state. (Chinga-Carrasco, 2018;Heggset et al, 2019;Mohan et al, 2020). The challenge is to retain the shape of the printed objects, especially upon drying, since 3D printed objects with high water content severely shrink, deform and crack.…”

Section: Introductionmentioning

confidence: 99%

Creaming Layers of Nanocellulose Stabilized Water-Based Polystyrene: High-Solids Emulsions for 3D Printing

Gestranius¹,

Kontturi²,

Mikkelson

et al. 2021

Front. Chem. Eng.

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Oil-in-water emulsions stabilized using cellulose nanofibrils (CNF) form extremely stable and high-volume creaming layers which do not coalesce over extended periods of time. The stability is a result of the synergistic action of Pickering stabilization and the formation of a CNF percolation network in the continuous phase. The use of methyl cellulose (MC) as a co-emulsifier together with CNF further increases the viscosity of the system and is known to affect the droplet size distribution of the formed emulsion. Here, we utilize these highly stable creaming layer systems for in situ polymerization of styrene with the aim to prepare an emulsion-based dope for additive manufacturing. We show that the approach exploiting the creaming layer enables the effortless water removal yielding a paste-like material consisting of polystyrene beads decorated with CNF and MC. Further, we report comprehensive characterization that reveals the properties and the performance of the creaming layer. Solid-state NMR measurements confirmed the successful polymerization taking place inside the nanocellulosic network, and size exclusion chromatography revealed average molecular weight (Mw) of polystyrene as approximately 700,000 Da. Moreover, the amount of the leftover monomer was found to be less than 1% as detected by gas chromatography. The dry solids content of the paste was ∼20% which is a significant increase compared to the solids content of the original CNF dispersion (1.7 wt%). The shrinkage of the CNF, MC and polystyrene structures upon drying—an often-faced challenge—was found to be acceptable for this composite containing highly hygroscopic biobased materials. At best, the two dimensional shrinkage was no more than ca. 20% which is significantly lower than the shrinkage of pure CNF being as high as 50%. The paste, which is a composite of biobased materials and a synthetic polymer, was demonstrated in direct-ink-writing to print small objects. With further optimization of the formulation, we find the emulsion templating approach as a promising route to prepare composite materials.

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Section: Introductionmentioning

confidence: 99%

Creaming Layers of Nanocellulose Stabilized Water-Based Polystyrene: High-Solids Emulsions for 3D Printing

Gestranius¹,

Kontturi²,

Mikkelson

et al. 2021

Front. Chem. Eng.

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“…[ 3 ] Among the bio‐based polymers considered, lignocellulosic polymers have attracted particular attention for AM over the past 5 years. [ 4–6 ] This stems in part from their large natural abundance—cellulose and lignin are the two most abundant biopolymers on earth—but also from their recent availability in purified and/ or nanoparticulate colloidal form from traditional pulp and paper processing and from biorefineries. [ 6 ] While most efforts in this arena have concentrated on AM of complete lignocellulose as fillers [ 5 ] or cellulosics, in particular nanocellulose and cellulose derivatives, [ 6 ] attempts at implementing lignin in AM remain scarce.…”

Section: Introductionmentioning

confidence: 99%

3D printing of lignin: Challenges, opportunities and roads onward

et al. 2021

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As the second most abundant biopolymer on earth, and as a resource recently becoming more available in separated and purified form on an industrial scale due to the development of new isolation technologies, lignin has a key role to play in transitioning our material industry towards sustainability. Additive manufacturing (AM), the most efficient‐material processing technology to date, has likewise made great strides to promote sustainable industrial solutions to our needs in engineered products. Bringing lignin research to AM has prompted the emergence of the nascent “lignin 3D printing” field. This review presents the recent state of art of this promising field and highlights its challenges and opportunities. Following a review of the industrial availability, molecular attributes, and associated properties of technical lignins, we review R&D efforts at implementing lignin systems in extrusion‐based and stereolithography (SLA) printing technologies. Doing so underlines the adage of lignin research that “all lignins are not created equal,” and stresses the opportunity nested in this chemical diversity created mostly by differences in isolation conditions to molecularly select and tune the attributes of technical lignin systems towards desirable properties, be it by modification or polymer blending. Considering the AM design process in its entirety, we finally propose onward routes to bring the full potential to this emerging field. We hope that this review can help promote the unique value and overdue industrial role of lignin in sustainable engineered materials and products.

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“…[11] Many types of reinforcement and fillers are currently being studied to be incorporated into these FDM 3D printing polymers to enhance the mechanical properties, interlayer adhesion for the 3D printing product to have properties comparable to those manufactured using injection molding. [12] For example, compared with a blank ABS sample, the incorporation of a small amount of reinforcement fillers such as multiwalled carbon nanotubes and carbon fibres into ABS improved the tensile stress, flexural strength, and modulus. [13,14] 3D printing direction of ABS polymer also has major effect on the strength of the printed product as much as 30% difference due to interlayer adhesion, therefore incorporation of fillers can be considered to enhance the interlayer adhesion as well as for better tensile properties.…”

Section: Introductionmentioning

confidence: 99%

Homogeneous distribution of lignin/graphene fillers with enhanced interlayer adhesion for 3D printing filament

et al. 2021

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The attention to pursuing biodegradable fillers as reinforcement in three-dimensional (3D) printing filament and enhancing interlayer adhesion has led to the exploitation of agricultural biomass. In this study, organosolv lignin fillers can act as the aforementioned twofold purposes in preparing acrylonitrile butadiene styrene (ABS) filament for fused deposition modeling (FDM). In this study, the lignin polymer composites were homogenized with graphene nanoplatelets (GnPs) as a reinforcer. Essentially, ABS 3D printing at 90 o with the reinforcement fillers shows a significant increment in the mechanical properties owing to better interlayer adhesion. The printed product promotes a substantial improvement on the tensile stress up to 29.1% compared with neat polymers. Furthermore, 3D printing using lignin/GnP composite filaments shows the feasibility of biofillers to be used as filaments for FDM 3D printing of complex geometries even though the surface finish has been affected.

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Extending Cellulose-Based Polymers Application in Additive Manufacturing Technology: A Review of Recent Approaches

Cited by 59 publications

References 175 publications

Creaming Layers of Nanocellulose Stabilized Water-Based Polystyrene: High-Solids Emulsions for 3D Printing

Creaming Layers of Nanocellulose Stabilized Water-Based Polystyrene: High-Solids Emulsions for 3D Printing

3D printing of lignin: Challenges, opportunities and roads onward

Homogeneous distribution of lignin/graphene fillers with enhanced interlayer adhesion for 3D printing filament

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