The hierarchical structure of keratin
makes it challenging
to process
without chemical modification. In this work, we show that using uniaxial
thermocompression of unrefined horn powder, it is possible to “mold”
the keratin macromolecules and process it like a convenience polymer,
by maintaining a certain moisture content and applying high pressure.
The processing window was delimited by the denaturation and thermal
degradation temperatures of keratin. The optimization of processing
parameters, such as moisture content, temperature, pressure, and holding
time, was conducted with the aim of improving the mechanical properties
of the resulting materials. Alternative thermocompression processes
implementing different heating and cooling techniques were also tested
and compared. The most important process parameter was the efficient
cooling step to keep the material under pressure along the entire
temperature cycle. The material obtained through this process exhibited
remarkable strength, stiffness, water resistance, and thermal stability,
making it a potential substitute for synthetic thermoplastic polymers
and currently available biobased materials (i.e., poly(lactic acid),
cellulose acetate). The study opens new avenues for further research
on other sources of scleroproteins and process optimization, offering
promising prospects for the development of biopolymer-based materials
with superior properties.