Additive manufacturing of lightweight structures: Microfibrillated cellulose - PLA biofoams

Halil L. Tekinalp, Stefan Dopatka, Tyler Smith, James Anderson, Douglas J. Gardner, Yousoo Han, William Peter, Soydan Ozcan

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

Extrusion-based polymer additive manufacturing (AM) technology is growing rapidly. The introduction of fiber reinforced feedstock materials and recent developments in the manufacturing systems have promulgated large scale AM of composites to create new industries and applications. Synthetic fibers such as carbon and glass fibers are commonly used to reinforce polymer composites. However, increasing environmental and long-term sustainability concerns are leading to new materials using cellulose fiber reinforcement in bio-derived polymers. These materials offer new property sets, new supply chains and have the potential to provide economical solutions leading to new applications. Large scale AM can be attractive for many different applications because of its ability to freeform manufacture complex geometries; each application may require different material properties. One of the novel application areas for large scale AM is 3D printing of lightweight materials via foaming. Although achieving low density is the key in light weighting via foaming, mechanical performance is also important for many applications. In this study the impact of micro-cellulose fibers (MFC) on foaming behavior and the mechanical properties of additively manufactured parts is investigated. MFC-polylactic acid (PLA) feedstock pellets were prepared at varying MFC content (5, 10, 15 and 20 wt.%) to understand the impact of cellulose fiber content on density and mechanical properties of the AM biocomposites. Also, the impact of extrusion speed and foaming agent content on the AM biocomposites is investigated. Although achieving uniform printed foam structure is challenging with the presence of cellulose fibers, promising results were accomplished with density values below 0.5g/cm3

Original languageEnglish
Title of host publicationComposites and Advanced Materials Expo, CAMX 2021
PublisherThe Composites and Advanced Materials Expo (CAMX)
Pages1034-1044
Number of pages11
ISBN (Electronic)9781934551400
StatePublished - 2021
Event8th Annual Composites and Advanced Materials Expo, CAMX 2021 - Dallas, United States
Duration: Oct 19 2021Oct 21 2021

Publication series

NameComposites and Advanced Materials Expo, CAMX 2021

Conference

Conference8th Annual Composites and Advanced Materials Expo, CAMX 2021
Country/TerritoryUnited States
CityDallas
Period10/19/2110/21/21

Keywords

  • Additive manufacturing
  • Biocomposites
  • Cellulose fiber
  • Foam
  • Lightweight
  • Microcellulose

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