Scientists at the Department of Energy’s Oak Ridge National Laboratory have created a recipe for a renewable 3D printing feedstock that could spur a profitable new use for an intractable biorefinery byproduct: lignin.
The discovery, detailed in Science Advances, expands ORNL’s achievements in lowering the cost of bioproducts by creating novel uses for lignin—the material left over from the processing of biomass. Lignin gives plants rigidity and also makes biomass resistant to being broken down into useful products.
“Finding new uses for lignin can improve the economics of the entire biorefining process,” said ORNL project lead Amit Naskar.
Researchers combined a melt-stable hardwood lignin with conventional plastic, a low-melting nylon, and carbon fiber to create a composite with just the right characteristics for extrusion and weld strength between layers during the printing process, as well as excellent mechanical properties.
The work is tricky. Lignin chars easily; unlike workhorse composites like acrylonitrile-butadiene-styrene (ABS) that are made of petroleum-based thermoplastics, lignin can only be heated to a certain temperature for softening and extrusion from a 3D-printing nozzle. Prolonged exposure to heat dramatically increases its viscosity—it becomes too thick to be extruded easily.
But when researchers combined lignin with nylon, they found a surprising result: the composite’s room temperature stiffness increased while its melt viscosity decreased. The lignin-nylon material had tensile strength similar to nylon alone and lower viscosity, in fact, than conventional ABS or high impact polystyrene.
The scientists conducted neutron scattering at the High Flux Isotope Reactor and used advanced microscopy at the Center for Nanophase Materials Science—both DOE Office of Science User Facilities at ORNL—to explore the composite’s molecular structure. They found that the combination of lignin and nylon “appeared to have almost a lubrication or plasticizing effect on the composite,” noted Naskar.
“Structural characteristics of lignin are critical to enhance 3D printability of the materials,” said ORNL’s Ngoc Nguyen who collaborated on the project.
Scientists were also able to mix in a higher percentage of lignin—40 to 50 percent by weight—a new achievement in the quest for a lignin-based printing material. ORNL scientists then added 4 to 16 percent carbon fiber into the mix. The new composite heats up more easily, flows faster for speedier printing, and results in a stronger product.
“ORNL’s world-class capabilities in materials characterization and synthesis are essential to the challenge of transforming byproducts like lignin into coproducts, generating potential new revenue streams for industry and creating novel renewable composites for advanced manufacturing,” said Moe Khaleel, associate laboratory director for Energy and Environmental Sciences.
The lignin-nylon composite is patent-pending and work is ongoing to refine the material and find other ways to process it.
The Latest on: 3D printing feedstock
via Google News
The Latest on: 3D printing feedstock
- UofL researchers piloting process to make healthy sugar and 3-D printable materials from soy hullson January 12, 2021 at 6:44 am
This project will pilot a commercially viable process using previous research to convert soybean hull biomass into a low-calorie, diabetic-friendly sugar substitute while simultaneously extracting ...
- 3D Metal Printer Uses Welding Wireon January 10, 2021 at 4:00 pm
Feedstock is supplied in filament form ... [Dominik Meffert] has done exactly this with his wire 3D printer project. Extruder cold end using a standard feeder roller For his filament, [Dominik ...
- The New Downstream Industry – Challenges and Opportunities Aheadon January 10, 2021 at 6:43 am
Introduction and Context The current scenario present great challenges to the crude oil refining industry, prices volatility of raw material, pressure from society to reduce environmental ...
- ReactionWare 3D Printed Medicineon January 6, 2021 at 4:01 pm
Yes thats correct actually printing medication. Using various feedstock of chemicals they see a future where manufacturing your medication from home will be possible. Using standard 3D printing ...
- How to avoid errors during desktop 3D printingon January 4, 2021 at 4:00 pm
The 3D Printer Experience in Chicago offers 3D printing ... Regardless of the plastic feedstock, 3D printers should be operated in a ventilated area because the plastic can emit fumes.
- Made In Space makes ceramic turbine part in orbit in another 3D printing milestoneon December 21, 2020 at 3:00 pm
Related: 3D printing in space: A photo gallery The blisk ... The recycler is designed to convert bags and other plastic trash into "feedstock" that can be used by the AMF printer.
- 3D Printing Market Size, Share, Sales Volume and Revenue Growth Analysis Research Report 2026on December 21, 2020 at 1:25 am
The product will convert the plastic waste generated by the 3D printer on the ISS into feedstock for the company's 3D printer, Additive Manufacturing Facility. March 2019: Optomec Inc. exhibited ...
- General Motors Veteran, Alan S. Batey Adds Deep Industry Experience to the Board of Uniformity Labson December 15, 2020 at 12:29 am
and metal feedstock producer that has pioneered revolutionary refining and printing processes that significantly enhance the 3D printing value proposition. Its feedstock materials and print ...
- Quality in Additive Manufacturing/3D Printingon August 9, 2019 at 11:11 am
feedstock variability, process unknowns, and limited process monitoring/control utilities. Build quality has been a serious roadblock to wider adoption of Additive Manufacturing/3D Printing (AM/3DP).
- Recycle at Home with 3D Printingon June 28, 2018 at 9:00 am
3D printing has disrupted transportation. With its ability to decentralize manufacturing, parts can be emailed and printed on location. However, the feedstock must be shipped. If you could find a ...
via Bing News