Shape fidelity and structure of 3D printed high consistency nanocellulose

Novel technologies for producing tridimensional cellulosic materials for packaging: A review

Petroleum-based packaging have been developed during the last century to transport and protect many products, regardless of the field of applications (food, electronics, cosmetics, leisure, etc.). Such protection has been very useful for the development of our society by favoring economic growth, limiting food waste and product deterioration, and consequently avoiding strong environmental impacts. An environmental concern has now been taken into consideration by numerous countries, with several legislations being promulgated to avoid or limit plastic waste. In this context, cellulose emerges as an alternative material for packaging applications since it is bio-based, biodegradable, and in most cases recyclable in an existing stream. However, most of the existing cellulose packaging is based on roll-to-roll 2D products or plied boxes and is not suitable to substitute plastics in 3D-shaped packaging. Recently, the interest in molded cellulose has increased exponentially thanks to new adaptations of raw materials and processes. Alternatively, research groups and companies try to adapt the injection molding to the production of cellulose-based packaging solutions. This review details for the first time the various processes and recent works in this direction. After proposing the basics of cellulose, this work focuses on the different types of molded cellulose and the novel strategies to produce 3D cellulose-based materials.

Three-Dimensional Printing of Lignocellulose Structures: Improving Mechanical Properties and Shape Fidelity

Additive manufacturing of nanocellulose (NC) materials is an emergent technological domain that facilitates the fabrication of complex and environment-friendly structures that mitigate greenhouse gas emissions. However, printing high concentrations of NC into intricate structures encounters substantial challenges due to inadequate adhesion between the printed layers attributed to a high cellulose solid content, resulting in low shape fidelity and mechanical properties. Therefore, to address these challenges, this paper reports lignin (LG) blending, a nanofiller, in high-content NC (>25 wt % solid content) paste to improve the layer adhesion of three-dimensional (3D) printed structures. The printed structures are dried in a clean room condition followed by postcuring. The optimized lignocellulose (0.5LG-NC) paste showed high structural shape fidelity, remarkable flexural strength, and moduli of 102.93 ± 0.96 MPa and 9.05 ± 0.07 GPa. Furthermore, the volumetric shrinkage behavior in box-like 3D printed structures with optimized LG-NC paste shows low standard deviations, demonstrating the repeatability of the printed structures. The study can be adapted for high-performance engineering and biomedical applications to manufacture high mechanical strength environment-friendly structures.

3D printing of concentrated nanocellulose material: The critical role of substrates on the shape fidelity and mechanical properties

This paper presents a breakthrough in the shape fidelity and mechanical strength of 3D-printed high-concentration nanocellulose structures, demonstrating a record flexural strength of 149 ± 2 MPa and a flexural modulus of 15 ± 0.8 GPa. These findings replace the previous method of 3D printing on conventional substrates with wood substrates for highly concentrated nanocellulose (HCNC) structures. The HCNC structures are 3D-printed using extrusion and processed under controlled drying conditions (Relative humidity: 60 % and 45 %, Temperature: 25 °C) to achieve outstanding mechanical properties without sacrificing structure shape fidelity/retention. It was noticed that the drying phenomenon of HCNC structures on the conventional substrates is responsible for the adhesion issues between the printed layers resulting in low shape fidelity/retention. In contrast with conventional substrates, the wood substrates offer an increased drying rate from the bottom side of printed HCNC structures due to its hydrophilicity and wicked nature, which helps maintain the shape fidelity without using additional crosslinkers, resulting in improved shape fidelity/retention and mechanical properties. The 3D-printed nanocellulose structure bears twice the load compared to a commercial poly lactic acid 3D-printed one. These features open a new horizon for fabricating 3D-printed nanocellulose structures for advanced environmentally friendly structural applications.

Collaboration of two-star nanomaterials: The applications of nanocellulose-based metal organic frameworks composites

Nanocellulose, as the star nanomaterial in carbohydrate polymers, has excellent mechanical properties, biodegradability, and easy chemical modification. However, further practical applications of nanocellulose are limited by their inadequate functionalization. Metal-organic frameworks (MOFs), as the star nanomaterial in functional polymers, have a large surface area, high porosity, and adjustable structure. The collaboration of nanocellulose and MOFs is a desirable strategy to make composites especially interesting for multifunctional and multi-field applications. What sparks will be produced by the collaboration of two-star nanomaterials? In this review article, we highlight an up-to-date overview of nanocellulose-based MOFs composites. The sewage treatment, gas separation, energy storage, and biomedical applications are mainly summarized. Finally, the challenges and research trends of nanocellulose-based MOFs composites are prospected. We hope this review may provide a valuable reference for the development and applications of carbohydrate polymer composites soon.

Additively-Manufactured High-Concentration Nanocellulose Composites: Structure and Mechanical Properties

Additive manufacturing technology (AMT) has transformed polymer composites' manufacturing process with its exceptional ability to construct complex products with unique materials, functions, and structures. Besides limiting studies of manufacturing arbitrarily shaped composites using AMT, printed structures with a high concentration of nanocellulose face adhesion issues upon drying, resulting in shape fidelity issues and low mechanical strength. This research demonstrates an economical approach to printing a high-concentration (25.46 wt%) nanocellulose (NC) layer-wise pattern to fabricate structures. Two different composites are fabricated: (1) 3D-printed pure and high-concentration (10, 15, and 20 wt%) polyvinyl-alcohol (PVA)-blended NC structures followed by freeze-drying and impregnation of Epofix resin by varying hardener contents; (2) 3D-printed PVA-blended NC green composites dried at cleanroom conditions (Relative humidity 45%; Temperature 25 °C). Different contents (10, 15, and 20 wt%) of PVA as a crosslinker were blended with NC to assist the printed layers' adhesions. An optimum PVA content of 15 wt% and an Epofix resin with 4 wt% hardener cases showed the highest bending strength of 55.41 ± 3.63 MPa and elastic modulus of 4.25 ± 0.37 GPa. In contrast, the 15 wt% PVA-blended NC cleanroom-dried green composites without resin infusion showed bending strength and elastic modulus of 94.78 ± 3.18 MPa and 9.00 ± 0.27 GPa, reflecting high interface adhesions as confirmed by scanning electron microscope. This study demonstrated that AMT-based nanocellulose composites could be scaled up for commercial use.

3D printable fully biomass-based composite using poly(furfuryl alcohol) as binder and cellulose as a filler

Nowadays, composite materials are widely used in different sectors owing to their improved mechanical and functional properties compared to bulk materials and efficient manufacturing processes. Nevertheless, the majority of these materials are still petroleum-based, which is incompatible with the recent environmental awareness. As a result, in the current study, a fully biomass-based composite material was produced employing poly(furfuryl alcohol) (PFA) as a bio-based matrix coupled with cellulose powder as fillers and processing aid agent. The addition of cellulose powder increased the viscosity of the uncured composite paste and conferred it a shear-thinning thixotropic making it suitable for 3D printing using the liquid deposition modeling technique (LDM). After curing, the combination of these raw materials yields a renewable and cost-effective composite for additive manufacturing by the LDM technique with high interlayer and interfilament adhesion, good mechanical performances, and adequate shape fidelity.

Progress, Challenge and Perspective of Fabricating Cellulose

Cellulose as the most abundant biopolymers on Earth, presents appealing performance in mechanical properties, thermal management, and versatile functionalization. The development of fabrication methods closely relates to enrich its functionality and reduce manufacture cost. However, cellulose is hard to be dissolved by most common solvents or melt due to its recalcitrant property. Herein, the recent progress of fabricating cellulose is summarized. First, the unique hierarchical structure of cellulose is fully investigated and the resulted processability is highlighted in directions of down to nanocellulose, dissolution, and thermoplastic processing. Then, the reported fabrication methods are summarized in three aspects: (1) self-assembly from nano/micro cellulose suspensions, especially the self-assembly of cellulose nanocrystals; (2) dissolution-regeneration-drying, covering spinning and solvent infusion processing; and (3) thermoplastic processing, focusing on analysis of the setup and the morphology changes of the prepared products. In each aspect, the flowchart of the fabrication process, the behind mechanism, fabricated products, and effects of processing parameters are explored. Finally, this review provides a perspective on the further direction of fabricating cellulose, especially the challenges toward mass production of cellulose. This article is protected by copyright. All rights reserved.

Deconstruction and Reassembly of Renewable Polymers and Biocolloids into Next Generation Structured Materials

This review considers the most recent developments in supramolecular and supraparticle structures obtained from natural, renewable biopolymers as well as their disassembly and reassembly into engineered materials. We introduce the main interactions that control bottom-up synthesis and top-down design at different length scales, highlighting the promise of natural biopolymers and associated building blocks. The latter have become main actors in the recent surge of the scientific and patent literature related to the subject. Such developments make prominent use of multicomponent and hierarchical polymeric assemblies and structures that contain polysaccharides (cellulose, chitin, and others), polyphenols (lignins, tannins), and proteins (soy, whey, silk, and other proteins). We offer a comprehensive discussion about the interactions that exist in their native architectures (including multicomponent and composite forms), the chemical modification of polysaccharides and their deconstruction into high axial aspect nanofibers and nanorods. We reflect on the availability and suitability of the latter types of building blocks to enable superstructures and colloidal associations. As far as processing, we describe the most relevant transitions, from the solution to the gel state and the routes that can be used to arrive to consolidated materials with prescribed properties. We highlight the implementation of supramolecular and superstructures in different technological fields that exploit the synergies exhibited by renewable polymers and biocolloids integrated in structured materials.

3D-Printable Nanocellulose-Based Functional Materials: Fundamentals and Applications

Nanomaterials obtained from sustainable and natural sources have seen tremendous growth in recent times due to increasing interest in utilizing readily and widely available resources. Nanocellulose materials extracted from renewable biomasses hold great promise for increasing the sustainability of conventional materials in various applications owing to their biocompatibility, mechanical properties, ease of functionalization, and high abundance. Nanocellulose can be used to reinforce mechanical strength, impart antimicrobial activity, provide lighter, biodegradable, and more robust materials for packaging, and produce photochromic and electrochromic devices. While the fabrication and properties of nanocellulose are generally well established, their implementation in novel products and applications requires surface modification, assembly, and manufacturability to enable rapid tooling and scalable production. Additive manufacturing techniques such as 3D printing can improve functionality and enhance the ability to customize products while reducing fabrication time and wastage of materials. This review article provides an overview of nanocellulose as a sustainable material, covering the different properties, preparation methods, printability and strategies to functionalize nanocellulose into 3D-printed constructs. The applications of 3D-printed nanocellulose composites in food, environmental, and energy devices are outlined, and an overview of challenges and opportunities is provided.

Recent advances in 3D printing of nanocellulose: structure, preparation, and application prospects

Emerging cellulose nanomaterials extracted from agricultural biomasses have recently received extensive attention due to diminishing fossil resources. To further reduce the carbon footprints and wastage of valuable resources, additive manufacturing techniques of new nanocellulosic materials have been developed. Studies on the preparation and characterization of 3D-printable functional nanocellulosic materials have facilitated a deeper understanding into their desirable attributes such as high surface area, biocompatibility, and ease of functionalization. In this critical review, we compare and highlight the different methods of extracting nanocellulose from biorenewable resources and the strategies for transforming the obtained nanocellulose into nanocomposites with high 3D printability. Optimistic technical applications of 3D-printed nanocellulose in biomedical, electronics, and environmental fields are finally described and evaluated for future perspectives.

Valorization of disposable COVID-19 mask through the thermo-chemical process

It becomes common to wear a disposable face mask to protect from coronavirus disease 19 (COVID-19) amid this pandemic. However, massive generations of contaminated face mask cause environmental concerns because current disposal processes (i.e., incineration and reclamation) for them release toxic chemicals. The disposable mask is made of different compounds, making it hard to be recycled. In this regard, this work suggests an environmentally benign disposal process, simultaneously achieving the production of valuable fuels from the face mask. To this end, CO₂-assisted thermo-chemical process was conducted. The first part of this work determined the major chemical constituents of a disposable mask: polypropylene, polyethylene, nylon, and Fe. In the second part, pyrolysis study was employed to produce syngas and C_1-2 hydrocarbons (HCs) from the disposable mask. To enhance syngas and C_1-2 HCs formations, multi-stage pyrolysis was used for more C-C and C-H bonds scissions of the disposable mask. Catalytic pyrolysis over Ni/SiO₂ further expedited H₂ and CH₄ formations due to its capability for dehydrogenation. In the presence of CO₂, catalytic pyrolysis additionally produced CO, while pyrolysis in N₂ did not produce it. Therefore, the thermo-chemical conversion of disposable face mask and CO₂ could be an environmentally benign way to remove COVID-19 plastic waste, generating value-added products.

Physical and Chemical Factors Influencing the Printability of Hydrogel-based Extrusion Bioinks

Bioprinting researchers agree that "printability" is a key characteristic for bioink development, but neither the meaning of the term nor the best way to experimentally measure it has been established. Furthermore, little is known with respect to the underlying mechanisms which determine a bioink's printability. A thorough understanding of these mechanisms is key to the intentional design of new bioinks. For the purposes of this review, the domain of printability is defined as the bioink requirements which are unique to bioprinting and occur during the printing process. Within this domain, the different aspects of printability and the factors which influence them are reviewed. The extrudability, filament classification, shape fidelity, and printing accuracy of bioinks are examined in detail with respect to their rheological properties, chemical structure, and printing parameters. These relationships are discussed and areas where further research is needed, are identified. This review serves to aid the bioink development process, which will continue to play a major role in the successes and failures of bioprinting, tissue engineering, and regenerative medicine going forward.

Assessment methodologies for extrusion-based bioink printability

Extrusion-based bioprinting is one of the leading manufacturing techniques for tissue engineering and regenerative medicine. Its primary limitation is the lack of materials, known as bioinks, which are suitable for the bioprinting process. The degree to which a bioink is suitable for bioprinting has been described as its 'printability.' However, a lack of clarity surrounding the methodologies used to evaluate a bioink's printability, as well as the usage of the term itself, have hindered the field. This article presents a review of measures used to assess the printability of extrusion-based bioinks in an attempt to assist researchers during the bioink development process. Many different aspects of printability exist and many different measurements have been proposed as a consequence. Researchers often do not evaluate a new bioink's printability at all, while others simply do so qualitatively. Several quantitative measures have been presented for the extrudability, shape fidelity, and printing accuracy of bioinks. Different measures have been developed even within these aspects, each testing the bioink in a slightly different way. Additionally, other relevant measures which had little or no examples of quantifiable methods are also to be considered. Looking forward, further work is needed to improve upon current assessment methodologies, to move towards a more comprehensive view of printability, and to standardize these printability measurements between researchers. Better assessment techniques will naturally lead to a better understanding of the underlying mechanisms which affect printability and better comparisons between bioinks. This in turn will help improve upon the bioink development process and the bioinks available for use in bioprinting.

Microtopography-Guided Radial Gradient Circle Array Film with Nanoscale Resolution

Distribution of multimaterials at arbitrary positions with nanoscale resolution and over a large area substrate is essential to future advances in functional graded materials. Such stringent requirements are highly beyond the reach of current techniques, although newly developed 3D printing technologies are addressed. Here, a radial gradient circle array film with the distribution accuracy up to ≈18 nm is fabricated by using microtopographic substrate. A mathematical model is developed to guide the distribution of position, size, shape, and type of materials on an arbitrary section for the given morphology of substrate. The periodic electrical and mechanical properties of the radial gradient circle film are identified, which can be beneficial for further functionalization and applications, such as gradient refractive index lenses, microcoils, and microantennas.