3D-Printed Thermoset Biocomposites Based on Forest Residues by Delayed Extrusion of Cold Masterbatch (DECMA)

Jon Trifol; Siddharth Jayaprakash; Hossein Baniasadi; Rubina Ajdary; Niklas Kretzschmar; Orlando J. Rojas; Jouni Partanen; Jukka V. Seppälä

doi:10.1021/acssuschemeng.1c05587

3D-Printed Thermoset Biocomposites Based on Forest Residues by Delayed Extrusion of Cold Masterbatch (DECMA)

Jon Trifol
, Siddharth Jayaprakash
, Hossein Baniasadi
, Rubina Ajdary
, Niklas Kretzschmar
, Orlando J. Rojas
, Jouni Partanen
, Jukka V. Seppälä^*

^*Corresponding author for this work

University of British Columbia

Research output: Contribution to journal › Article › Scientific › peer-review

16 Citations (Scopus)

201 Downloads (Pure)

Abstract

We developed a 3D-printing process based on thermoset biocomposites termed Delayed Extrusion of Cold Masterbatch (DECMA). DECMA is a processing method, based on controlling the degree of curing, that takes some responsibility of the 3D printing from materials and as such can be used to 3D print otherwise unprintable materials. First, a masterbatch was produced by mixing a bio-based resin (bioepoxy) and sawdust and lignin. This paste was partially cured at room temperature until reaching an apparent viscosity suitable for extrusion (≈10⁵ mPa·s at 1 s^-1). The system was next cooled (5-10 °C) to delay subsequent hardening prior to 3D printing. The printability of the biocomposite paste was systematically investigated and the merits of the delayed extrusion, via DECMA, were assessed. It was found that DECMA allowed the revalorization of sawdust and lignin via 3D printing, as direct printing led to failed prints. Our approach afforded cost-effective, shear-thinning dopes with a high bio-based content (58-71%). The bio-based 3D-printed materials demonstrated good machinability by computer numerical control (CNC). Overall, the benefits of the introduced DECMA method are shown for processing bio-based materials and for on-demand solidification during additive manufacturing.

Original language	English
Pages (from-to)	13979–13987
Number of pages	9
Journal	ACS Sustainable Chemistry & Engineering
Volume	9
Issue number	41
Early online date	4 Oct 2021
DOIs	https://doi.org/10.1021/acssuschemeng.1c05587
Publication status	Published - 18 Oct 2021
MoE publication type	A1 Journal article-refereed

Funding

Dr. J.T. is grateful for the support of the Academy of Finland’s Flagship Programme under Projects Nos. 318890 and 318891 (Competence Center for Materials Bioeconomy, FinnCERES). The authors acknowledge the funding support by the Academy of Finland’s BioFuture2025 program under project 2228357-4 (3D Manufacturing of Novel Biomaterials) and the provision of facilities by Aalto University at OtaNano Nanomicroscopy Center (Aalto-NMC). The authors also acknowledge Ashish Mohite for the elaboration of the G-code for the honeycomb structure and Kari Kääriäinen for the post-processing of 3D-printed parts with a CNC machine.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 7 Affordable and Clean Energy
SDG 12 Responsible Consumption and Production

Keywords

3D printing
biocomposites
DECMA
forest residues
paste extrusion
thermoset

Access to Document

10.1021/acssuschemeng.1c05587Licence: CC BY

CHEM_Trifol_et_al_3D-Printed_Thermoset_Biocomposites_2021_ACS_Sustainable_Chemistry_and_EngineeringFinal published version, 5.02 MBLicence: CC BY

Cite this

@article{ca8338aec64d4987bfe5bd72d3dcb072,

title = "3D-Printed Thermoset Biocomposites Based on Forest Residues by Delayed Extrusion of Cold Masterbatch (DECMA)",

abstract = "We developed a 3D-printing process based on thermoset biocomposites termed Delayed Extrusion of Cold Masterbatch (DECMA). DECMA is a processing method, based on controlling the degree of curing, that takes some responsibility of the 3D printing from materials and as such can be used to 3D print otherwise unprintable materials. First, a masterbatch was produced by mixing a bio-based resin (bioepoxy) and sawdust and lignin. This paste was partially cured at room temperature until reaching an apparent viscosity suitable for extrusion (≈105 mPa·s at 1 s-1). The system was next cooled (5-10 °C) to delay subsequent hardening prior to 3D printing. The printability of the biocomposite paste was systematically investigated and the merits of the delayed extrusion, via DECMA, were assessed. It was found that DECMA allowed the revalorization of sawdust and lignin via 3D printing, as direct printing led to failed prints. Our approach afforded cost-effective, shear-thinning dopes with a high bio-based content (58-71\%). The bio-based 3D-printed materials demonstrated good machinability by computer numerical control (CNC). Overall, the benefits of the introduced DECMA method are shown for processing bio-based materials and for on-demand solidification during additive manufacturing. ",

keywords = "3D printing, biocomposites, DECMA, forest residues, paste extrusion, thermoset",

author = "Jon Trifol and Siddharth Jayaprakash and Hossein Baniasadi and Rubina Ajdary and Niklas Kretzschmar and Rojas, \{Orlando J.\} and Jouni Partanen and Sepp{\"a}l{\"a}, \{Jukka V.\}",

note = "Funding Information: Dr. J.T. is grateful for the support of the Academy of Finland{\textquoteright}s Flagship Programme under Projects Nos. 318890 and 318891 (Competence Center for Materials Bioeconomy, FinnCERES). The authors acknowledge the funding support by the Academy of Finland{\textquoteright}s BioFuture2025 program under project 2228357-4 (3D Manufacturing of Novel Biomaterials) and the provision of facilities by Aalto University at OtaNano Nanomicroscopy Center (Aalto-NMC). The authors also acknowledge Ashish Mohite for the elaboration of the G-code for the honeycomb structure and Kari K{\"a}{\"a}ri{\"a}inen for the post-processing of 3D-printed parts with a CNC machine. Publisher Copyright: {\textcopyright} 2021 The Authors. Published by American Chemical Society.",

year = "2021",

month = oct,

day = "18",

doi = "10.1021/acssuschemeng.1c05587",

language = "English",

volume = "9",

pages = "13979–13987",

journal = "ACS Sustainable Chemistry \& Engineering",

issn = "2168-0485",

publisher = "American Chemical Society",

number = "41",

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T1 - 3D-Printed Thermoset Biocomposites Based on Forest Residues by Delayed Extrusion of Cold Masterbatch (DECMA)

AU - Trifol, Jon

AU - Jayaprakash, Siddharth

AU - Baniasadi, Hossein

AU - Ajdary, Rubina

AU - Kretzschmar, Niklas

AU - Rojas, Orlando J.

AU - Partanen, Jouni

AU - Seppälä, Jukka V.

N1 - Funding Information: Dr. J.T. is grateful for the support of the Academy of Finland’s Flagship Programme under Projects Nos. 318890 and 318891 (Competence Center for Materials Bioeconomy, FinnCERES). The authors acknowledge the funding support by the Academy of Finland’s BioFuture2025 program under project 2228357-4 (3D Manufacturing of Novel Biomaterials) and the provision of facilities by Aalto University at OtaNano Nanomicroscopy Center (Aalto-NMC). The authors also acknowledge Ashish Mohite for the elaboration of the G-code for the honeycomb structure and Kari Kääriäinen for the post-processing of 3D-printed parts with a CNC machine. Publisher Copyright: © 2021 The Authors. Published by American Chemical Society.

PY - 2021/10/18

Y1 - 2021/10/18

N2 - We developed a 3D-printing process based on thermoset biocomposites termed Delayed Extrusion of Cold Masterbatch (DECMA). DECMA is a processing method, based on controlling the degree of curing, that takes some responsibility of the 3D printing from materials and as such can be used to 3D print otherwise unprintable materials. First, a masterbatch was produced by mixing a bio-based resin (bioepoxy) and sawdust and lignin. This paste was partially cured at room temperature until reaching an apparent viscosity suitable for extrusion (≈105 mPa·s at 1 s-1). The system was next cooled (5-10 °C) to delay subsequent hardening prior to 3D printing. The printability of the biocomposite paste was systematically investigated and the merits of the delayed extrusion, via DECMA, were assessed. It was found that DECMA allowed the revalorization of sawdust and lignin via 3D printing, as direct printing led to failed prints. Our approach afforded cost-effective, shear-thinning dopes with a high bio-based content (58-71%). The bio-based 3D-printed materials demonstrated good machinability by computer numerical control (CNC). Overall, the benefits of the introduced DECMA method are shown for processing bio-based materials and for on-demand solidification during additive manufacturing.

AB - We developed a 3D-printing process based on thermoset biocomposites termed Delayed Extrusion of Cold Masterbatch (DECMA). DECMA is a processing method, based on controlling the degree of curing, that takes some responsibility of the 3D printing from materials and as such can be used to 3D print otherwise unprintable materials. First, a masterbatch was produced by mixing a bio-based resin (bioepoxy) and sawdust and lignin. This paste was partially cured at room temperature until reaching an apparent viscosity suitable for extrusion (≈105 mPa·s at 1 s-1). The system was next cooled (5-10 °C) to delay subsequent hardening prior to 3D printing. The printability of the biocomposite paste was systematically investigated and the merits of the delayed extrusion, via DECMA, were assessed. It was found that DECMA allowed the revalorization of sawdust and lignin via 3D printing, as direct printing led to failed prints. Our approach afforded cost-effective, shear-thinning dopes with a high bio-based content (58-71%). The bio-based 3D-printed materials demonstrated good machinability by computer numerical control (CNC). Overall, the benefits of the introduced DECMA method are shown for processing bio-based materials and for on-demand solidification during additive manufacturing.

KW - 3D printing

KW - biocomposites

KW - DECMA

KW - forest residues

KW - paste extrusion

KW - thermoset

UR - https://www.scopus.com/pages/publications/85117343889

U2 - 10.1021/acssuschemeng.1c05587

DO - 10.1021/acssuschemeng.1c05587

M3 - Article

AN - SCOPUS:85117343889

SN - 2168-0485

VL - 9

SP - 13979

EP - 13987

JO - ACS Sustainable Chemistry & Engineering

JF - ACS Sustainable Chemistry & Engineering

IS - 41

ER -

3D-Printed Thermoset Biocomposites Based on Forest Residues by Delayed Extrusion of Cold Masterbatch (DECMA)

Abstract

Funding

UN SDGs

Keywords

Access to Document

Other files and links

Fingerprint

FinnCERES: Competence Center for the Materials Bioeconomy: A Flagship for our Sustainable Future

3D-manufacturing of novel biomaterials

3D-manufacturing of novel biomaterials

OtaNano

OtaNano - Nanomicroscopy Center

Cite this

3D-Printed Thermoset Biocomposites Based on Forest Residues by Delayed Extrusion of Cold Masterbatch (DECMA)

Abstract

Funding

UN SDGs

Keywords

Access to Document

Other files and links

Fingerprint

Projects

FinnCERES: Competence Center for the Materials Bioeconomy: A Flagship for our Sustainable Future

3D-manufacturing of novel biomaterials

3D-manufacturing of novel biomaterials

Equipment

OtaNano

OtaNano - Nanomicroscopy Center

Cite this