A path for lignin valorization via additive manufacturing of high-performance sustainable composites with enhanced 3D printability

Nguyen, Ngoc A.; Barnes, Sietske H.; Bowland, Christopher C.; Meek, Kelly M.; Littrell, Kenneth C.; Keum, Jong K.; Naskar, Amit K.

doi:10.1126/sciadv.aat4967

Title: A path for lignin valorization via additive manufacturing of high-performance sustainable composites with enhanced 3D printability

Journal Article · 14 December 2018 · Science Advances

DOI: https://doi.org/10.1126/sciadv.aat4967 · OSTI ID:1489603

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Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Here, we report the manufacture of printable, sustainable polymer systems to address global challenges associated with high-volume utilization of lignin, an industrial waste from biomass feedstock. By analyzing a common three-dimensional printing process—fused-deposition modeling—and correlating the printing-process features to properties of materials such as acrylonitrile-butadiene-styrene (ABS) and nylon, we devised a first-of-its-kind, high-performance class of printable renewable composites containing 40 to 60 weight % (wt %) lignin. An ABS analog made by integrating lignin into nitrile-butadiene rubber needs the presence of a styrenic polymer to avoid filament buckling during printing. However, lignin-modified nylon composites containing 40 to 60 wt % sinapyl alcohol–rich, melt-stable lignin exhibit enhanced stiffness and tensile strength at room temperature, while—unexpectedly—demonstrating a reduced viscosity in the melt. Further, incorporation of 4 to 16 wt % discontinuous carbon fibers enhances mechanical stiffness and printing speed, as the thermal conductivity of the carbon fibers facilitates heat transfer and thinning of the melt. We found that the presence of lignin and carbon fibers retards nylon crystallization, leading to low-melting imperfect crystals that allow good printability at lower temperatures without lignin degradation.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1489603

Journal Information:: Science Advances, Vol. 4, Issue 12; ISSN 2375-2548

Publisher:: AAASCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 107 works

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A fundamental understanding of whole biomass dissolution in ionic liquid for regeneration of fiber by solution-spinning Nguyen, Ngoc A.; Kim, Keonhee; Bowland, Christopher C. Green Chemistry, Vol. 21, Issue 16 https://doi.org/10.1039/c9gc00774a	journal	January 2019
Automatic Transformation of Membrane‐Type Electronic Devices into Complex 3D Structures via Extrusion Shear Printing and Thermal Relaxation of Acrylonitrile–Butadiene–Styrene Frameworks Jang, Hun Soo; Yoo, Seonggwang; Kang, Seong Hyeon Advanced Functional Materials, Vol. 30, Issue 5 https://doi.org/10.1002/adfm.201907384	journal	November 2019
Desirable plant cell wall traits for higher-quality miscanthus lignocellulosic biomass da Costa, Ricardo M. F.; Pattathil, Sivakumar; Avci, Utku Biotechnology for Biofuels, Vol. 12, Issue 1 https://doi.org/10.1186/s13068-019-1426-7	journal	April 2019
An Ionomeric Renewable Thermoplastic from Lignin‐Reinforced Rubber Barnes, Sietske H.; Goswami, Monojoy; Nguyen, Ngoc A. Macromolecular Rapid Communications https://doi.org/10.1002/marc.201900059	journal	April 2019
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Stereolithography 3D Printing of Lignin-Reinforced Composites with Enhanced Mechanical Properties Zhang, Shuyang; Li, Mi; Hao, Naijia ACS Omega, Vol. 4, Issue 23 https://doi.org/10.1021/acsomega.9b02455	journal	November 2019
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