Polylactic acid-agave fiber biocomposites produced by rotational molding: A comparative study with compression molding

Characterization of Microalgae Biomass-Based Composites Obtained through Rotational Molding

The wide range of applications and the numerous advantages of plastics have led to their excessive use, with subsequent damage to ecosystems. As an environmentally friendly alternative, biocomposites have gained much attention, and microalgae have become a potential source for their production. In this study, the use of washed and unwashed Spirulina in polyethylene-based composites has been evaluated as a way to prevent the thermooxidation of polyethylene, while at the same time, reducing the amount of virgin plastic used. Biocomposites were produced by rotomolding, testing different biomass contents and determining their mechanical and thermal performances as well as their water uptake level. Composites with up to 15% of biomass (by weight), a particularly high ratio for rotomolding, were satisfactorily produced. Using 5% of both biomasses did not significantly modify the behavior when compared with the neat PE samples' properties. For higher loadings, the use of non-washed biomass allowed us to obtain better properties, with added benefits related to using an unwashed biomass (less water consumption, lower costs and fewer environmental impacts). On the other hand, this study showed a promising beneficial effect on the thermooxidative resistance of composites, as the oxidation induction times were notably increased with biomass addition.

An examination of recent research of water absorption behavior of natural fiber reinforced polylactic acid (PLA) composites: A review

Researchers have begun focusing on developing biodegradable materials, such as natural fiber/polymer composites (NFPC), since the growing of environmental concerns related to waste management. One crucial aspect that must be established in the development of these composites is their water-absorption behavior. This paper examines the water absorption (WA) behavior of NFPC, with a specific emphasis on natural fiber/polylactic acid (PLA) composites. It discusses processes and numerous aspects related to this behavior, based on recent published research. This review analyzes the influence of several factors, such as the loading of natural fiber, the combination of different natural fibers, the methods used in manufacturing, and the temperature of the water, on the WA behavior of natural fiber/PLA composites. It also explores how WA affects the properties of these composites. In addition, this review also presented techniques for improving the WA resistance of the composites. This review paper provides researchers with insights into the WA behavior of the composites, aiming to facilitate the development of a versatile and eco-friendly material that may effectively address waste disposal challenges.

Mechanical Performance of Rotationally Molded Multilayer mLDPE/Banana-Fiber Composites

The incorporation of materials different from the polymer within the rotational molding process usually results in lowered mechanical properties, where impact strength is of particular concern. In order to overcome this issue, multilayer structures of virgin polyethylene (PE) and banana fiber composites were prepared to determine the impact of the different layers on the performance of the final part. Cycle time has been studied to identify the influence of the addition of fibers in the process. The tensile, flexural and impact properties have been analyzed, finding improvements in Young's modulus of up to 13%, although at the expense of significant decreases in impact strength. A reduction in the fiber size due to the pulverization process was observed, which affected the rheological and mechanical behavior of the composite. The beneficial effects of working in multiple layers have been demonstrated in this work, where composites with up to 5% of banana fiber have been produced in two-layer structures. Finally, the need to add neat polyethylene in the external layer is also highlighted as a way to counteract the reductions in mechanical properties, particularly for flexural elastic modulus and tensile strength, and this also helps with the drop in impact behavior to a lower extent.

Recent Developments in Inorganic Composites in Rotational Molding

Rotational molding allows for obtaining hollow parts with good aesthetics and properties, having as main drawbacks the lack of pressure and the long cycle times, which limit the range of materials. Different fillers have been introduced in rotomolding to obtain composite materials assessed. This review has shown that glass fibers or particles are the most common material among them, although carbon fibers or clays have also been studied. In general terms, 10% loadings provide an increase in mechanical properties; higher loadings usually lead to a decrease in processability or final properties. When the filler consists of a micro- or nano-material, such as clay or graphene, lower loadings are proposed, generally not exceeding 3%. The use of fillers of an inorganic nature to obtain composites has not been as explored as the incorporation of lignocellulosic materials and even less if referring to waste materials or side streams from industrial processes. So, there is a broad field for assessing the processing and properties of rotomolded composites containing inorganic waste materials, including the study of the relationship between the ratio of filler/reinforcement and the final properties and also their preprocessing (dry blending vs. melting compounding).

Use of Ricinus communis shredded material as filler in rotational molded parts to improve the bio-disintegration behavior

This paper focuses on the use of castor oil plant (Ricinus communis) as filler in rotomolded parts using polyethylene (PE) and polylactic acid (PLA) as polymer matrixes. The vegetable shredded material was used in 5 and 10% weight following a dry blending procedure and then rotomolded to obtain cube test parts. This material was characterized to determine its chemical composition, thermal stability, and structure. The NaOH-treated material shows reduced hemicellulose content and higher thermal stability. Obtained composite materials were characterized in terms of mechanical (tensile, flexural, and impact) and thermal properties, morphology, and bio-disintegration behavior. The use of Ricinus as filler in rotomolded PE composite decreases, in general terms, mechanical properties of neat PE, while no significant changes in thermal or bio-disintegration properties are found. On the contrary, PLA composites show higher tensile strength and similar Young's modulus than the matrix, although with reduced flexural and impact properties. Alkali-treated Ricinus material produces parts with higher porosity and thus, lower mechanical properties than composites with untreated material. Finally, the incorporation of this vegetal material modifies to a great extent the thermal properties of the PLA matrix. The bio-disintegration rate increases due to the use of fibers, probably because of the higher moisture absorption of composites.

The Relationship between a Rotational Molding Processing Procedure and the Structure and Properties of Biobased Polyethylene Composites Filled with Expanded Vermiculite

Rotational molding is a technology in which polymeric thin-walled products can be made. The newest descriptions of this technology concern the possibility of obtaining polymer composite materials. There are two main methods of incorporating fillers into a polymer matrix. Dry blending is based on mixing fillers with polymer powders before rotational molding by hand or using automatic mixers. In the melt compounding method, fillers are mixed with the polymer in the preliminary step by melt processing and then grinding or pulverization to obtain polymer powders for rotational molding. This work aimed to investigate the impact of the processing procedure on the structure and properties of biobased composites with expanded vermiculite. Produced rotomolded parts were examined using mechanical tests to assess changes in tensile, flexural, and impact properties. The most significant difference in mechanical properties was noted for samples with 10 wt% expanded vermiculite (EV). The elasticity modulus increases by almost 2 fold when the sample is prepared in a two-step process, the tensile strength is 4-fold higher, the flexural modulus is 3-fold higher, and the flexural strength is 5-fold higher. We also investigated thermomechanical properties in DMA measurement. The void volume content was also measured to control the quality of obtained parts. The porosity of dry blended samples containing more than 2 wt% EV is almost 2-fold higher. Other methods to control quality and structure were optical and scanning electron microscopy used for rotomolded parts and polymer powders. The investigations of rotomolded parts were supplemented with a complete description of used materials, including the particle size distributions of polymer powders and filler. Analysis of the thermal properties and chemical structure was also performed despite all the mechanical tests. The emerging conclusions from the research clearly show that the two-step process allows for achieving a more beneficial mechanical performance of the composites made of the biobased polymer in rotational molding technology.

The Effect of Plasma Treatment of Polyethylene Powder and Glass Fibers on Selected Properties of Their Composites Prepared via Rotational Molding

In this article, the effect of plasma treatment of polyethylene powder and glass fibers on the adhesion between polyethylene and glass fibers in composites prepared by rotational molding was studied. In contrast to other processing techniques, such as injection molding, the rotational molding process operates at atmospheric pressure, and no pressure is added to ensure mechanical interlocking. This makes reinforcing the rotomolded product very difficult. Therefore, the formation of chemical bonds is necessary for strong adhesion. Different combinations of untreated polyethylene (UT.PE), plasma-treated polyethylene (PT.PE), untreated and plasma-treated glass fibers were manually mixed and processed by rotational molding. The resulting composites were cut and tested to demonstrate the effect of the treatment on the adhesion between the composite components and on the mechanical properties of the final composites. The results showed that the treatment of both powder and fiber improved the adhesion between the matrix and fibers, thus improving the mechanical properties of the resulting composites compared to those of pure polyethylene samples and composites prepared using untreated components. The tensile strength, tensile modulus, and flexural modulus of the composites prepared using 10-min treated powder with 20 wt% of 40-min treated fibers improved by 20%, 82%, and 98%, respectively, compared to the pure polyethylene samples.

Additive manufacturing technology of polymeric materials for customized products: recent developments and future prospective

The worldwide demand for additive manufacturing (AM) is increasing due to its ability to produce more challenging customized objects based on the process parameters for engineering applications. The processing of conventional materials by AM processes is a critically demanded research stream, which has generated a path-breaking scenario in the rapid manufacturing and upcycling of plastics. The exponential growth of AM in the worldwide polymer market is expected to exceed 20 billion US dollars by 2021 in areas of automotive, medical, aerospace, energy and customized consumer products. The development of functional polymers and composites by 3D printing-based technologies has been explored significantly due to its cost-effective, easier integration into customized geometries, higher efficacy, higher precision, freedom of material utilization as compared to traditional injection molding, and thermoforming techniques. Since polymers are the most explored class of materials in AM to overcome the limitations, this review describes the latest research conducted on petroleum-based polymers and their composites using various AM techniques such as fused filament fabrication (FFF), selective laser sintering (SLS), and stereolithography (SLA) related to 3D printing in engineering applications such as biomedical, automotive, aerospace and electronics.

Agave By-Products: An Overview of Their Nutraceutical Value, Current Applications, and Processing Methods

Agave, commonly known as “maguey” is an important part of the Mexican tradition and economy, and is mainly used for the production of alcoholic beverages, such as tequila. Industrial exploitation generates by-products, including leaves, bagasse, and fibers, that can be re-valorized. Agave is composed of cellulose, hemicellulose, lignin, fructans, and pectin, as well as simple carbohydrates. Regarding functional properties, fructans content makes agave a potential source of prebiotics with the capability to lower blood glucose and enhance lipid homeostasis when it is incorporated as a prebiotic ingredient in cookies and granola bars. Agave also has phytochemicals, such as saponins and flavonoids, conferring anti-inflammatory, antioxidant, antimicrobial, and anticancer properties, among other benefits. Agave fibers are used for polymer-based composite reinforcement and elaboration, due to their thermo-mechanical properties. Agave bagasse is considered a promising biofuel feedstock, attributed to its high-water efficiency and biomass productivity, as well as its high carbohydrate content. The optimization of physical and chemical pretreatments, enzymatic saccharification and fermentation are key for biofuel production. Emerging technologies, such as ultrasound, can provide an alternative to current pretreatment processes. In conclusion, agaves are a rich source of by-products with a wide range of potential industrial applications, therefore novel processing methods are being explored for a sustainable re-valorization of these residues.

Valorization of Invasive Plants from Macaronesia as Filler Materials in the Production of Natural Fiber Composites by Rotational Molding

This paper compares the mechanical properties of different natural fiber composites produced by rotational molding as a way of waste valorization from campaigns to control invasive plant species in Macaronesia. Rotomolded parts produced with polymeric matrices (polyethylene) and filled with up to 20% by weight of cellulosic fibers obtained from Arundo donax L., Pennisetum setaceum, and Ricinus communis plants were characterized in terms of tensile, flexural, and impact strength. It was found that the sieving of natural fibers allowed for their introduction in higher loadings, from 10 (for un-sieved material) to 20%; fiber size greatly affected the mechanical properties of the final parts, although some combinations were proven not to reduce the mechanical properties of the neat resin. This study is a first approach to the valorization of residues obtained from periodic campaigns of the control of invasive species performed by public authorities, usually at the local level. It is important to highlight that the main objective of this research did not focus on economically profitable activity; instead, it was focused on the reduction of wastes to be disposed from ecosystem maintenance actions and the investment of potential income into preservation policies.

Mechanical and Physicochemical Properties of 3D-Printed Agave Fibers/Poly(lactic) Acid Biocomposites

In order to provide a second economic life to agave fibers, an important waste material from the production of tequila, filaments based on polylactic acid (PLA) were filled with agave fibers (0, 3, 5, 10 wt%), and further utilized to produce biocomposites by fused deposition modeling (FDM)-based 3D printing at two raster angles (−45°/45° and 0°/90°). Differential scanning calorimetry, water uptake, density variation, morphology, and composting of the biocomposites were studied. The mechanical properties of the biocomposites (tensile, flexural, and Charpy impact properties) were determined following ASTM international norms. The addition of agave fibers to the filaments increased the crystallinity value from 23.7 to 44.1%. However, the fibers generated porous structures with a higher content of open cells and lower apparent densities than neat PLA pieces. The printing angle had a low significant effect on flexural and tensile properties, but directly affected the morphology of the printed biocomposites, positively influenced the impact strength, and slightly improved the absorption values for biocomposites printed at −45°/45°. Overall, increasing the concentrations of agave fibers had a detrimental effect on the mechanical properties of the biocomposites. The disintegration of the biocomposites under simulated composting conditions was slowed 1.6-fold with the addition of agave fibers, compared to neat PLA.

Rotational Molding of Poly(Lactic Acid)/Polyethylene Blends: Effects of the Mixing Strategy on the Physical and Mechanical Properties

In this study, blends of poly(lactic acid) (PLA)/linear medium density polyethylene (LMDPE) at different weight ratios were prepared by rotational molding. Two mixing strategies were used to evaluate the effect of phase dispersion on the physical and mechanical properties: (i) Dry-blending (DB) using a high shear mixer, and (ii) melt-blending (MB) using a twin-screw extruder. Thermal, morphological, and mechanical analyses were performed on the neat polymers and their blends. The thermal analysis was completed by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), and the blends prepared by MB had lower thermal stability than the ones prepared via DB due to some thermo-oxidative degradation through the double thermal process (extrusion and rotomolding). The morphology of the rotomolded parts showed that DB generated larger particle sizes (around 500 µm) compared to MB (around 5 µm) due to the shear and elongational stresses applied during extrusion. The tensile and flexural properties of the rotomolded parts combined the PLA stiffness with the LMDPE toughness independent of the blending technique. Neat PLA presented increments in tensile strength (54%) and flexural strength (111%) for DB compared with MB. A synergistic effect in impact strength was observed in blends with 12 and 25 wt. % of PLA prepared by DB.

Torrefaction of Coffee Husk Flour for the Development of Injection-Molded Green Composite Pieces of Polylactide with High Sustainability

Coffee husk, a major lignocellulosic waste derived from the coffee industry, was first ground into flour of fine particles of approximately 90 µm and then torrefied at 250 °C to make it more thermally stable and compatible with biopolymers. The resultant torrefied coffee husk flour (TCHF) was thereafter melt-compounded with polylactide (PLA) in contents from 20 to 50 wt% and the extruded green composite pellets were shaped by injection molding into pieces and characterized. Although the incorporation of TCHF reduced the ductility and toughness of PLA, filler contents of 20 wt% successfully yielded pieces with balanced mechanical properties in both tensile and flexural conditions and improved hardness. Contents of up to 30 wt% of TCHF also induced a nucleating effect that favored the formation of crystals of PLA, whereas the thermal degradation of the biopolyester was delayed by more than 7 °C. Furthermore, the PLA/TCHF pieces showed higher thermomechanical resistance and their softening point increased up to nearly 60 °C. Therefore, highly sustainable pieces were developed through the valorization of large amounts of coffee waste subjected to torrefaction. In the Circular Bioeconomy framework, these novel green composites can be used in the design of compostable rigid packaging and food contact disposables.

Rotational Molding of Linear Low-Density Polyethylene Composites Filled with Wheat Bran

Application of lignocellulosic fillers in the manufacturing of wood polymer composites (WPCs) is a very popular trend of research, however it is still rarely observed in the case of rotational molding. The present study aimed to analyze the impact of wheat bran content (from 2.5 wt.% to 20 wt.%) on the performance of rotationally-molded composites based on a linear low-density polyethylene (LLDPE) matrix. Microscopic structure (scanning electron microscopy), as well as physico-mechanical (density, porosity, tensile performance, hardness, rebound resilience, dynamic mechanical analysis), rheological (oscillatory rheometry) and thermo-mechanical (Vicat softening temperature) properties of composites were investigated. Incorporation of 2.5 wt.% and 5 wt.% of wheat bran did not cause significant deterioration of the mechanical performance of the material, despite the presence of ‘pin-holes’ at the surface. Values of tensile strength and rebound resilience were maintained at a very similar level, while hardness was slightly decreased, which was associated with the porosity of the structure. Higher loadings resulted in the deterioration of mechanical performance, which was also expressed by the noticeable rise of the adhesion factor. For lower loadings of filler did not affect the rheological properties. However, composites with 10wt.% and 20 wt.% also showed behavior suitable for rotational molding. The presented results indicate that the manufacturing of thin-walled products based on wood polymer composites via rotational molding should be considered a very interesting direction of research.

Processing of Super Tough Plasticized PLA by Rotational Molding

This work is aimed at studying the suitability of polylactic acid (PLA) plasticized by two cardanol derivatives, i.e., cardanol and epoxidized cardanol acetate, in rotational molding, for the production of hollow items. For this purpose, plasticized PLA samples were obtained by melt mixing and then processed by a lab-scale rotational molding equipment. For comparison, poly(ethylene glycole), PEG, and plasticized PLA samples were also produced. Despite the very low cooling rates attained in rotational molding, completely amorphous samples were obtained with neat PLA and PLA plasticized by cardanol derivatives. In contrast, PEG plasticized PLA showed a very high degree of crystallinity, as highlighted by DSC and XRD analysis, which made the extraction of the rotomolded box-shaped specimens impossible. The plasticizing effectiveness of cardanol derivatives was proven by tensile testing of rotational molded prototypes, which highlighted the reduced modulus and strength and improved strain to break, compared to neat PLA. Therefore, efficient toughening of PLA can be attained by the use of the two cardanol derived plasticizers, which involves a significant reduction of the polymer glass transition, as well as a reduced increase of the crystallization kinetic. On the other hand, the reduction of the glass transition temperature due to the addition of plasticizer is responsible for significant crystallization effects even during ageing at room temperature, which involves significant embrittlement of the material.