Engineering flame retardant biodegradable polymer nanocomposites and their application in 3D printing

Development of Flame-Retardant Polylactic Acid Formulations for Additive Manufacturing

Polymeric materials, renowned for their lightweight attributes and design adaptability, play a pivotal role in augmenting fuel efficiency and cost-effectiveness in railway vehicle development. The tailored formulation of compounds, specifically designed for additive manufacturing, holds significant promise in expanding the use of these materials. This study centers on poly(lactic acid) (PLA), a natural-based biodegradable polymeric material incorporating diverse halogen-free flame retardants (FRs). Our investigation scrutinizes the printability and fire performance of these formulations, aligning with the European railway standard EN 45545-2. The findings underscore that FR in the condensed phase, including ammonium polyphosphate (APP), expandable graphite (EG), and intumescent systems, exhibit superior fire performance. Notably, FR-inducing hydrolytic degradation, such as aluminum hydroxide (ATH) or EG, reduces polymer molecular weight, significantly impacting PLA's mechanical performance. Achieving a delicate balance between fire resistance and mechanical properties, formulations with APP as the flame retardant emerge as optimal. This research contributes to understanding the fire performance and printability of 3D-printed PLA compounds, offering vital insights for the rail industry's adoption of polymeric materials.

Innovative Electrospun Nanofiber Mats Based on Polylactic Acid Composited with Silver Nanoparticles for Medical Applications

Nanofibers are some of the most attractive materials that can modify functionalities for developing new kinds of specific applications and are mainly used as a biomedical material. Herein, we designed and prepared antibacterial nonwoven fiber mats of PLA and PLA composited with Ag nanoparticles by electrospinning. The effects of varying filler contents on their chemical, surface morphology, thermal, water absorbency, and antibacterial properties were investigated using FTIR, SEM/EDS, DSC, swelling ratio, and qualitative and quantitative antibacterial tests. FTIR and EDS spectra indicated that Ag nanoparticles were incorporated in the PLA without chemical bonding. SEM revealed that the average diameter of the PLA nanofibers containing the Ag nanoparticles was more significant than those without those particles. In addition, fiber diameters are proportional to the amount of Ag nanoparticle contents. DSC indicated that the Ag nanoparticles can be incorporated within the PLA matrix without strongly affecting their thermal properties. Moreover, the crystallinity of the composite nonwoven fiber mats was higher than those of fiber mats in the neat PLA. However, TGA revealed that the loaded Ag can improve the thermal stability of the PLA electrospun fiber mats. Accordingly, the antibacterial activities revealed that all the composite nanofiber mats exhibited excellent resistance against S. aureus and E. coli bacterial strains. In addition, in the cell toxicity study, all produced hybrids of nonwoven fiber mats induced a reduction in cell viability for the L929 fibroblast cells. Our results suggest that the designed and prepared nonwoven fiber mats may have good potential for use in the biomedical field, particularly in wound dressing applications.

Recent Advances and Outlook in 2D Nanomaterial-Based Flame-Retardant PLA Materials

Poly (lactic acid) or polylactide (PLA) has gained widespread use in many industries and has become a commodity polymer. Its potential as a perfect replacement for petrochemically made plastics has been constrained by its extreme flammability and propensity to flow in a fire. Traditional flame-retardants (FRs), such as organo-halogen chemicals, can be added to PLA without significantly affecting the material's mechanical properties. However, the restricted usage of these substances causes them to bioaccumulate and endanger plants and animals. Research on PLA flame-retardants has mostly concentrated on organic and inorganic substances for the past few years. Meanwhile, there has been a significant increase in renewed interest in creating environmentally acceptable flame-retardants for PLA to maintain the integrity of the polymer, which is the current trend. This article reviews recent advancements in novel FRs for PLA. The emphasis is on two-dimensional (2D) nanosystems and the composites made from them that have been used to develop PLA nanocomposite (NCP) systems that are flame retarding. The association between FR loadings and efficiency for different FR-PLA systems is also briefly discussed in the paper, as well as their influence on processing and other material attributes. It is unmistakably established from the literature that adding 2D nanoparticles to PLA matrix systems reduces their flammability by forming an intumescent char/carbonized surface layer. This creates a barrier effect that successfully blocks the filtration of volatiles and oxygen, heat and mass transfer, and the release of combustible gases produced during combustion.

A road map on synthetic strategies and applications of biodegradable polymers

Biodegradable polymers have emerged as fascinating materials due to their non-toxicity, environmentally benign nature and good mechanical strength. The toxic effects of non-biodegradable plastics paved way for the development of sustainable and biodegradable polymers. The engineering of biodegradable polymers employing various strategies like radical ring opening polymerization, enzymatic ring opening polymerization, anionic ring opening polymerization, photo-initiated radical polymerization, chemoenzymatic method, enzymatic polymerization, ring opening polymerization and coordinative ring opening polymerization have been discussed in this review. The application of biodegradable polymeric nanoparticles in the biomedical field and cosmetic industry is considered to be an emerging field of interest. However, this review mainly highlights the applications of selected biodegradable polymers like polylactic acid, poly(ε-caprolactone), polyethylene glycol, polyhydroxyalkanoates, poly(lactide-co-glycolide) and polytrimethyl carbonate in various fields like agriculture, biomedical, biosensing, food packaging, automobiles, wastewater treatment, textile and hygiene, cosmetics and electronic devices.

Epoxy/melamine polyphosphate modified silicon carbide composites: Thermal conductivity and flame retardancy analyses

Silicon carbide (SiC) was modified by melamine polyphosphate (MPP)-modified silicone to form SiC-MPP, then incorporated into epoxy resin (EP) for developing thermally resistant composites, which showed thermal conductivity and flame retardancy performance. The EP/SiC-MPP composites were prepared by blending and cured under 60°C for 2 h and 150°C for 8 h. The grafting degree of SiC-MPP was analyzed using Fourier transform Infrared, scanning electron microscope, and thermogravimetric measurements. The flame retardancy of the EP/SiC-MPP composites was studied by UL-94 vertical combustion and cone calorimetry test. The results showed that for EP/SiC-MPP containing 20 wt%, the UL-94 was case V1. Also compared to pure epoxy, the peak heat release rate (PHRR) of composites was reduced from 800 to 304 kW·m−2. The thermal conductivity of EP/SiC-M20 composites was 0.53 W·m−1·K−1, almost 2.5-fold higher than pure epoxy (0.21 W·m−1·K−1). The as-prepared EP/SiC-MPP composites exhibited enhanced flame retardancy and thermal conductivity. Based on analyses performed, these composites took credit-related applications.

Physicochemical Characterization and Finite Element Analysis-Assisted Mechanical Behavior of Polylactic Acid- Montmorillonite 3D Printed Nanocomposites

This work aims to improve the properties of poly(lactic acid) (PLA) for future biomedical applications by investigating the effect of montmorillonite (MMT) nanoclay on physicochemical and mechanical behavior. PLA nanocomposite filaments were fabricated using different amounts of MMT (1.0, 2.0, and 4.0 wt.%) and 2 wt.% Joncryl chain extenders. The 3D-printed specimens were manufactured using Fused Filament Fabrication (FFF). The composites were characterized by Gel Permeation Chromatography (GPC), Melt Flow Index (MFI), X-ray Diffraction (XRD), and Fourier-transform infrared spectroscopy (FTIR). The thermal properties were studied by means of Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). Moreover, the hydrophilicity of the PLA/MMT nanocomposites was investigated by measuring the water contact angle. The mechanical behavior of the PLA/MMT nanocomposites was examined with nanoindentation, compression tests, and Dynamic Mechanical Analysis (DMA). The presence of Joncryl, as well as the pretreatment of MMT before filament fabrication, improved the MMT distribution in the nanocomposites. Furthermore, MMT enhanced the printability of PLA and improved the hydrophilicity of its surface. In addition, the results of nanoindentation testing coupled with Finite Element Analysis showed that as the MMT weight fraction increased, as well as an increased Young’s modulus. According to the results of the mechanical analysis, the best mechanical behavior was achieved for PLA nanocomposite with 4 wt.% MMT.

Synergistic Flame Retardancy of Phosphatized Sesbania Gum/Ammonium Polyphosphate on Polylactic Acid

Phosphating sesbania gum (DESG) was obtained by modifying sesbania gum (SG) with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and endic anhydride (EA). The structure of DESG was determined using Fourier transform infrared (FTIR) spectroscopy and nuclear magnetic resonance spectroscopy (¹H-NMR). Flame-retardant polylactic acid (PLA) composites were prepared by melt-blending PLA with DESG, which acted as a carbon source, and ammonium polyphosphate (APP), which acted as an acid source and a gas source. The flame retardancy of the PLA composite was investigated using vertical combustion (UL-94), the limiting oxygen index (LOI) and the cone calorimeter (CONE) test. Thermal properties and morphology were characterized via thermogravimetric analysis (TGA) and field emission scanning electron microscopy (FESEM), respectively. Experimental results indicated that when the mass ratio of DESG/APP was equal to 12/8 the LOI value was 32.2%; a vertical burning test (UL-94) V-0 rating was achieved. Meanwhile, the sample showed a lowest total heat release (THR) value of 52.7 MJ/m², which is a 32.5% reduction compared to that of neat PLA. Using FESEM, the uniform distribution of DESG and APP in the PLA matrix was observed. The synergistic effect of DESG and APP effectively enhanced the flame retardancy of PLA. Additionally, the synergistic mechanism of DESG and APP in PLA was proposed.

Flame-Retarding Properties of Injected and 3D-Printed Intumescent Bio-Based PLA Composites: The Influence of Brønsted and Lewis Acidity of Montmorillonite

The influence of processing intumescent bio-based poly(lactic acid) (PLA) composites by injection and fused filament fabrication (FFF) was evaluated. A raw (ANa) and two acidic-activated (AH2 and AH5) montmorillonites were added to the intumescent formulation, composed by lignin and ammonium polyphosphate, in order to evaluate the influence of the strength and the nature (Brønsted or Lewis) of their acidic sites on the fire behavior of the composites. The thermal stability and the volatile thermal degradation products of the composites were assessed. The injected and 3D-printed composites were submitted to cone calorimeter (CC), limit oxygen index (LOI), and UL-94 flammability tests. A similar tendency was observed for the injected and 3D-printed samples. The high density of strong Lewis sites in AH2 showed to be detrimental to the fire-retarding properties. For the CC test, the addition of the intumescent composite reduced the peak of heat released (pHRR) in approximately 49% when compared to neat PLA, while the composites containing ANa and AH5 presented a reduction of at least 54%. However, the addition of AH2 caused a pHRR reduction of around 47%, close to the one of the composite without clay (49%). In the LOI tests, the composites containing ANa and AH5 achieved the best results: 39% and 35%, respectively, for the injected samples, and 35 and 38% for the 3D-printed samples. For the composite containing AH2 the LOI values were 34% and 32% for injected and 3D-printed samples, respectively. Overall, the best performance in the flammability tests was achieved by the composites containing clays with only weak and moderate strength acidic sites (ANa and AH5).

Mechanically Robust and Flame-Retardant Polylactide Composites Based on In Situ Formation of Crosslinked Network Structure by DCP and TAIC

The addition of intumescent flame retardant to PLA can greatly improve the flame retardancy of the material and inhibit the dripping, but the major drawback is the adverse impact of the mechanical properties of the material. In this study, we found that the flame retardant and mechanical properties of the materials can be improved simultaneously by constructing a cross-linked structure. Firstly, a cross-linking flame-retardant PLA structure was designed by adding 0.9 wt% DCP and 0.3 wt% TAIC. After that, different characterization methods including torque, melt flow rate, molecular weight and gel content were used to clarify the formation of crosslinking structures. Results showed that the torque of 0.9DCP/0.3TAIC/FRPLA increased by 307% and the melt flow rate decreased by 77.8%. The gel content of 0.9DCP/0.3TAIC/FRPLA was 30.8%, indicating the formation of cross-linked structures. Then, the mechanical properties and flame retardant performance were studied. Results showed that, compared with FRPLA, the tensile strength, elongation at break and impact strength of 0.9DCP/0.3TAIC/FRPLA increased by 34.8%, 82.6% and 42.9%, respectively. The flame retardancy test results showed that 0.9DCP/0.3TAIC/FRPLA had a very high LOI (the limiting oxygen index) value of 39.2% and passed the UL94 V-0 level without dripping. Finally, the crosslinking reaction mechanism, flame retardant mechanism and the reasons for the improvement of mechanical properties were studied and described.

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.

Biomimetic Hierarchical Structuring of PLA by Ultra-Short Laser Pulses for Processing of Tissue Engineered Matrices: Study of Cellular and Antibacterial Behavior

The influence of ultra-short laser modification on the surface morphology and possible chemical alteration of poly-lactic acid (PLA) matrix in respect to the optimization of cellular and antibacterial behavior were investigated in this study. Scanning electron microscopy (SEM) morphological examination of the processed PLA surface showed the formation of diverse hierarchical surface microstructures, generated by irradiation with a range of laser fluences (F) and scanning velocities (V) values. By controlling the laser parameters, diverse surface roughness can be achieved, thus influencing cellular dynamics. This surface feedback can be applied to finely tune and control diverse biomaterial surface properties like wettability, reflectivity, and biomimetics. The triggering of thermal effects, leading to the ejection of material with subsequent solidification and formation of raised rims and 3D-like hollow structures along the processed zones, demonstrated a direct correlation to the wettability of the PLA. A transition from superhydrophobic (θ > 150°) to super hydrophilic (θ < 20°) surfaces can be achieved by the creation of grooves with V = 0.6 mm/s, F = 1.7 J/cm2. The achieved hierarchical architecture affected morphology and thickness of the processed samples which were linked to the nature of ultra-short laser-material interaction effects, namely the precipitation of temperature distribution during material processing can be strongly minimized with ultrashort pulses leading to non-thermal and spatially localized effects that can facilitate volume ablation without collateral thermal damage The obtained modification zones were analyzed employing Fourier transform infrared (FTIR), X-ray photoelectron spectroscopy (XPS), Energy dispersive X-ray analysis (EDX), and optical profilometer. The modification of the PLA surface resulted in an increased roughness value for treatment with lower velocities (V = 0.6 mm/s). Thus, the substrate gains a 3D-like architecture and forms a natural matrix by microprocessing with V = 0.6 mm/s, F = 1.7 J/cm2, and V = 3.8 mm/s, F = 0.8 J/cm2. The tests performed with Mesenchymal stem cells (MSCs) demonstrated that the ultra-short laser surface modification altered the cell orientation and promoted cell growth. The topographical design was tested also for the effectiveness of bacterial attachment concerning chosen parameters for the creation of an array with defined geometrical patterns.

Tactile and Thermal Sensors Built from Carbon-Polymer Nanocomposites-A Critical Review

This paper provides a critical review of tactile and thermal sensors which are built from carbon nanomaterial-filled polymer composites (CNPCs). To make the review more comprehensive and systematic, the sensors are viewed as a system, and a general knowledge architecture for a system called function-context-behavior-principle-state-structure (FCBPSS) is employed to classify information as well as knowledge related to CNPC sensors. FCBPSS contains six basic concepts, namely, F: function, C: context, B: behavior, P: principle, and SS: state and structure. As such, the principle that explains why such composites can work as temperature and pressure sensors, various structures of the CNPC sensor, which realize the principle, and the behavior and performance of CNPC sensors are discussed in this review. This review also discusses the fabrication of the CNPC sensor. Based on the critical review and analysis, the future directions of research on the CNPC sensor are discussed; in particular, the need to have a network of CNPC sensors that can be installed on curved bodies such as those of robots is elaborated.

Theoretical Design of Biodegradable Phthalic Acid Ester Derivatives in Marine and Freshwater Environments

The biodegradability of phtalic acid esters in marine and freshwater environments was characterized by their binding free energy with corresponding degrading enzymes. According to comprehensive biodegradation effects weights, the binding free energy values were converted into dimensionless efficacy coefficient using ratio normalization method. Then, considering comprehensive dual biodegradation effects value and the structural parameters of PAEs in both marine and freshwater environments, a 3D‐QSAR pharmacophore model was constructed, five PAE derivatives (DBP−COOH, DBP−CHO, DBP−OH, DINP−NH₂, and DINP−NO₂) were screened out based on their environmental friendliness, functionality and stability. The prediction of biodegradation effects on five PAE derivatives by biodegradation models in marine and freshwater environment increased by 15.90 %, 15.84 %, 27.21 %, 12.33 %, and 8.32 %, and 21.57 %, 15.21 %, 20.99 %, 15.10 %, and 9.74 %, respectively. By simulating the photodegradation path of the PAE derivative molecular, it was found that DBP−OH can generate ^.OH and provides free radicals for the photodegradation of microplastics in the environment.

Highly thermally conductive boron nitride@UHMWPE composites with segregated structure

Highly thermally conductive boron nitride (BN)@ultra-high molecular weight polyethylene (UHMWPE) composites with the segregated structure were fabricated by powder mixing and hot pressing. Scanning electron microscopy and polarizing optical microscopy were used to analyze the dispersion of BN particles in the UHMWPE matrix. The morphology observation shows that BN particles are selectively located at the interfaces of UHMWPE particles and form continuous thermally conductive networks after the compression molding process. As a result, the thermal conductivity of the BN@UHMWPE composite increases to 3.37 W m−1 K−1 with 38.3 vol% BN, which is seven times larger than that of the pure UHMWPE. Furthermore, the incorporation of BN also influences the crystallinity and thermal properties of UHMWPE.

Additive Manufacturing and Textiles—State-of-the-Art

The application of additive manufacturing, well known as 3D printing, in textile industry is not more totally new. It allows is giving significant increase of the product variety, production stages reduction, widens the application areas of textiles, customization of design and properties of products according to the type of applications requirement. This paper presents a review of the current state-of-the-art, related to complete process of additive manufacturing. Beginning with the design tools, the classical machinery building computer-aided design (CAD) software, the novel non-uniform rational B-spline (NURBS) based software and parametric created models are reported. Short overview of the materials demonstrates that in this area few thermoplastic materials become standards and currently a lot of research for the application of new materials is going. Three types of 3D printing, depending on the relation to textiles, are identified and reported from the literature—3D printing on textiles, 3D printing of flexible structures and 3D printing with flexible materials. Several applications with all these methods are reported and finally the main advantages and disadvantages of the 3D printing in relation to textile industry are given.

The influence of roughness on stem cell differentiation using 3D printed polylactic acid scaffolds

With the increase in popularity of 3D printing, an important question arises as to the equivalence between devices manufactured by standard methods vs. those presenting with identical bulk specifications, but manufactured via fused deposition modeling (FDM) printing. Using thermal imaging in conjunction with electron and atomic force microscopy, we demonstrate that large thermal gradients, whose distribution is difficult to predict, are associated with FDM printing and result in incomplete fusion and sharkskin of the printing filament. Even though these features are micro or submicron scale, and hence may not interfere with the intended function of the device, they can have a profound influence if the device comes in contact with living tissue. Dental pulp stem cells were cultured on substrates of identical dimensions, which were either printed or molded from the same PLA stock material. The cultures exhibited significant differences in plating efficiency, migration trajectory, and morphology at early times stemming from attempts by the cells to minimize cytoplasm deformation as they attempt to adhere on the printed surfaces. Even though biomineralization without dexamethasone induction was observed in all cultures at later times, different gene expression patterns were observed on the two surfaces. (Osteogenic markers were upregulated on molded substrates, while odontogenic markers were upregulated on the FDM printed surfaces.) Our results clearly indicate that the method of manufacturing is an important consideration in comparing devices, which come in contact with living tissues.

Preparation of γ-Divinyl-3-Aminopropyltriethoxysilane Modified Lignin and Its Application in Flame Retardant Poly(lactic acid)

Lignin can be a candidate as a charring agent applied in halogen-free flame retardant polymers, and incorporation of silicon and nitrogen elements in lignin can benefit to enhancing its thermal stability and charring ability. In the present work, wheat straw alkali lignin (Lig) was modified to incorporate silicon and nitrogen elements by γ-divinyl-3-aminopropyltriethoxysilane, and the modified lignin (CLig) was combined with ammonium polyphosphate (APP) as intumescent flame retardant to be applied in poly(Lactic acid) (PLA). The flame retardancy, combustion behavior and thermal stability of PLA composites were studied by the limited oxygen index (LOI), vertical burning testing (UL-94), cone calorimetry testing (CCT) and thermogravimetric analysis (TGA), respectively. The results showed a significant synergistic effect between CLig and APP in flame retarded PLA (PLA/APP/CLig) occured, and the PLA/APP/CLig had better flame retardancy. CCT data analysis revealed that CLig and APP largely reduced the peak heat release rate (PHRR) and total heat release rate (THR) of PLA, indicating their effectiveness in decreasing the combustion of PLA. TGA results exhibited that APP and CLig improved the thermal stability of PLA at high temperature. The analysis of morphology and structure of residual char indicated that a continuous, compact and intumescent char layer on the material surface formed during firing, and had higher graphitization degree. Mechanical properties data showed that PLA/APP/CLig had higher tensile strength as well as elongation at break.

Nanofiller Reinforced Biodegradable PLA/PHA Composites: Current Status and Future Trends

The increasing demand for environmental protection has led to the rapid development of greener and biodegradable polymers, whose creation provided new challenges and opportunities for the advancement of nanomaterial science. Biodegradable polymer materials and even nanofillers (e.g., natural fibers) are important because of their application in greener industries. Polymers that can be degraded naturally play an important role in solving public hazards of polymer materials and maintaining ecological balance. The inherent shortcomings of some biodegradable polymers such as weak mechanical properties, narrow processing windows, and low electrical and thermal properties can be overcome by composites reinforced with various nanofillers. These biodegradable polymer composites have wide-ranging applications in different areas based on their large surface area and greater aspect ratio. Moreover, the polymer composites that exploit the synergistic effect between the nanofiller and the biodegradable polymer matrix can lead to enhanced properties while still meeting the environmental requirement. In this paper, a broad review on recent advances in the research and development of nanofiller reinforced biodegradable polymer composites that are used in various applications, including electronics, packing materials, and biomedical uses, is presented. We further present information about different kinds of nanofillers, biodegradable polymer matrixes, and their composites with specific concern to our daily applications.