Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Shuvodeep De; Shalini J. Rukmani; Xianhui Zhao; Caitlyn Clarkson; Frederic Vautard; Samarthya Bhagia; Monojoy Goswami; Shuyang Zhang; Sana F. Elyas; Wei Zhao; Jeremy C. Smith; Arthur J. Ragauskas; Soydan Ozcan; Halil Tekinalp; Muqing Si; Jinrui Huang; Ximin He

doi:10.1002/adfm.202414222

Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Shuvodeep De, Shalini J. Rukmani, Xianhui Zhao, Caitlyn Clarkson, Frederic Vautard, Samarthya Bhagia, Monojoy Goswami, Shuyang Zhang, Sana F. Elyas, Wei Zhao, Jeremy C. Smith, Arthur J. Ragauskas, Soydan Ozcan, Halil Tekinalp, Muqing Si, Jinrui Huang, Ximin He

Research output: Contribution to journal › Review article › peer-review

Abstract

Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. This review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

Original language	English
Journal	Advanced Functional Materials
DOIs	https://doi.org/10.1002/adfm.202414222
State	Accepted/In press - 2024

Funding

S.D. and S.J.R. contributed equally to this work. This review is based upon work supported by the US Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Office (AMMTO), Oak Ridge National Laboratory/University of Maine SMART program with research and resources used at the Manufacturing Demonstration Facility (MDF), a DOE AMMTO User Facility, and the Advanced Structures and Composites Center (ASCC), a University of Maine research center under CPS Agreements 35714 and 38563, the Bioenergy Technologies Office (BETO), the Oak Ridge Leadership Computing Facility, a DOE Office of Science User Facility, Johnson & Johnson WiSTEM2D Scholars Award, Moore Inventor Fellow award, and American Chemical Society PRF award 66747\u2010ND7. The authors thank Dr. Shih\u2010Hsien Liu for his input on co\u2010solvent screening through combined MD simulations and experiments to reduce CNF fibrillation energy.

Keywords

additive manufacturing
composites
fibrillation
finite element modeling
molecular dynamics
nanocellulose

UN SDGs

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

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De, S., Rukmani, S. J., Zhao, X., Clarkson, C., Vautard, F., Bhagia, S., Goswami, M., Zhang, S., Elyas, S. F., Zhao, W., Smith, J. C., Ragauskas, A. J., Ozcan, S., Tekinalp, H., Si, M., Huang, J., & He, X. (Accepted/In press). Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications. Advanced Functional Materials. https://doi.org/10.1002/adfm.202414222

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abstract = "Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. This review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.",

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AU - De, Shuvodeep

AU - Rukmani, Shalini J.

AU - Zhao, Xianhui

AU - Clarkson, Caitlyn

AU - Vautard, Frederic

AU - Bhagia, Samarthya

AU - Goswami, Monojoy

AU - Zhang, Shuyang

AU - Elyas, Sana F.

AU - Zhao, Wei

AU - Smith, Jeremy C.

AU - Ragauskas, Arthur J.

AU - Ozcan, Soydan

AU - Tekinalp, Halil

AU - Si, Muqing

AU - Huang, Jinrui

AU - He, Ximin

PY - 2024

Y1 - 2024

N2 - Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. This review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

AB - Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. This review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

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KW - finite element modeling

KW - molecular dynamics

KW - nanocellulose

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JO - Advanced Functional Materials

JF - Advanced Functional Materials

ER -

Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Abstract

Funding

Keywords

UN SDGs

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