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

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

doi:10.1002/adfm.202414222

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

Journal Article · 29 December 2024 · Advanced Functional Materials

DOI: https://doi.org/10.1002/adfm.202414222 · OSTI ID:2502181

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^[1]; Vautard, Frederic ^[1]; Bhagia, Samarthya ^[1];

^[1]; Zhang, Shuyang ^[3]; Elyas, Sana F. ^[1]; Zhao, Wei ^[4];

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^[1]; Tekinalp, Halil ^[1]; Si, Muqing ^[7]; Huang, Jinrui ^[7];

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Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Molecular Biophysics; Univ. of Tennessee, Knoxville, TN (United States)
Univ. of Tennessee, Knoxville, TN (United States)
Oklahoma State Univ., Stillwater, OK (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Molecular Biophysics
Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Univ. of California, Los Angeles, CA (United States)

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

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Bioenergy Technologies Office (BETO); USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2502181

Journal Information:: Advanced Functional Materials, Journal Name: Advanced Functional Materials Journal Issue: 7 Vol. 35; ISSN 1616-301X

Publisher:: WileyCopyright Statement

Country of Publication:: United States

Language:: English

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Thermal Conductivity of Cellulose Fibers in Different Size Scales and Densities Antlauf, Mathis; Boulanger, Nicolas; Berglund, Linn Biomacromolecules, Vol. 22, Issue 9 https://doi.org/10.1021/acs.biomac.1c00643	journal	August 2021
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3D Bioprinting Human Chondrocytes with Nanocellulose–Alginate Bioink for Cartilage Tissue Engineering Applications Markstedt, Kajsa; Mantas, Athanasios; Tournier, Ivan Biomacromolecules, Vol. 16, Issue 5 https://doi.org/10.1021/acs.biomac.5b00188	journal	April 2015
Using COSMO-RS to Predict Hansen Solubility Parameters Wojeicchowski, José Pedro; Ferreira, Ana M.; Okura, Tifany Industrial & Engineering Chemistry Research, Vol. 61, Issue 42 https://doi.org/10.1021/acs.iecr.2c01592	journal	July 2022
Use of Microfibrillated Cellulose/Lignosulfonate Blends as Carbon Precursors: Impact of Hydrogel Rheology on 3D Printing Shao, Ying; Chaussy, Didier; Grosseau, Philippe Industrial & Engineering Chemistry Research, Vol. 54, Issue 43 https://doi.org/10.1021/acs.iecr.5b02763	journal	October 2015
Development of a New Coarse-Grained Model to Simulate Assembly of Cellulose Chains Due to Hydrogen Bonding Wu, Zijie; Beltran-Villegas, Daniel J.; Jayaraman, Arthi Journal of Chemical Theory and Computation, Vol. 16, Issue 7 https://doi.org/10.1021/acs.jctc.0c00225	journal	June 2020
New Patchy Particle Model with Anisotropic Patches for Molecular Dynamics Simulations: Application to a Coarse-Grained Model of Cellulose Nanocrystal Rolland, Nicolas; Mehandzhiyski, Aleksandar Y.; Garg, Mohit Journal of Chemical Theory and Computation, Vol. 16, Issue 6 https://doi.org/10.1021/acs.jctc.0c00259	journal	May 2020
Extending the Martini 3 Coarse-Grained Force Field to Carbohydrates Lutsyk, Valery; Wolski, Pawel; Plazinski, Wojciech Journal of Chemical Theory and Computation, Vol. 18, Issue 8 https://doi.org/10.1021/acs.jctc.2c00553	journal	July 2022
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Water as an Intrinsic Structural Element in Cellulose Fibril Aggregates Chen, Pan; Wohlert, Jakob; Berglund, Lars The Journal of Physical Chemistry Letters, Vol. 13, Issue 24 https://doi.org/10.1021/acs.jpclett.2c00781	journal	June 2022
A Combined Theoretical and Experimental Study of the Polymer Matrix-Mediated Stress Transfer in a Cellulose Nanocomposite Peterson, Anna; Mehandzhiyski, Aleksandar Y.; Svenningsson, Leo Macromolecules, Vol. 54, Issue 7 https://doi.org/10.1021/acs.macromol.0c02305	journal	March 2021
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Tuning Glass Transition in Polymer Nanocomposites with Functionalized Cellulose Nanocrystals through Nanoconfinement Qin, Xin; Xia, Wenjie; Sinko, Robert Nano Letters, Vol. 15, Issue 10 https://doi.org/10.1021/acs.nanolett.5b02588	journal	September 2015
Tuning the Nanotopography and Chemical Functionality of 3D Printed Scaffolds through Cellulose Nanocrystal Coatings Babi, Mouhanad; Riesco, Roberto; Boyer, Louisa ACS Applied Bio Materials, Vol. 4, Issue 12 https://doi.org/10.1021/acsabm.1c00970	journal	November 2021
Poplar as Biofiber Reinforcement in Composites for Large-Scale 3D Printing Zhao, Xianhui; Tekinalp, Halil; Meng, Xianzhi ACS Applied Bio Materials, Vol. 2, Issue 10 https://doi.org/10.1021/acsabm.9b00675	journal	August 2019
Volumetric Double-Layer Charge Storage in Composites Based on Conducting Polymer PEDOT and Cellulose Sahalianov, Ihor; Say, Mehmet Girayhan; Abdullaeva, Oliya S. ACS Applied Energy Materials, Vol. 4, Issue 8 https://doi.org/10.1021/acsaem.1c01850	journal	August 2021
Computational Microscopy of PEDOT:PSS/Cellulose Composite Paper Mehandzhiyski, Aleksandar Y.; Zozoulenko, Igor ACS Applied Energy Materials, Vol. 2, Issue 5 https://doi.org/10.1021/acsaem.9b00307	journal	May 2019
Matrix-Assisted Three-Dimensional Printing of Cellulose Nanofibers for Paper Microfluidics Shin, Sungchul; Hyun, Jinho ACS Applied Materials & Interfaces, Vol. 9, Issue 31 https://doi.org/10.1021/acsami.7b07609	journal	July 2017
3D Printing of Photocurable Cellulose Nanocrystal Composite for Fabrication of Complex Architectures via Stereolithography Palaganas, Napolabel B.; Mangadlao, Joey Dacula; de Leon, Al Christopher C. ACS Applied Materials & Interfaces, Vol. 9, Issue 39 https://doi.org/10.1021/acsami.7b09223	journal	April 2017
Biomimetic Inks Based on Cellulose Nanofibrils and Cross-Linkable Xylans for 3D Printing Markstedt, Kajsa; Escalante, Alfredo; Toriz, Guillermo ACS Applied Materials & Interfaces, Vol. 9, Issue 46 https://doi.org/10.1021/acsami.7b13400	journal	November 2017
Lignin-Containing Photoactive Resins for 3D Printing by Stereolithography Sutton, Jordan T.; Rajan, Kalavathy; Harper, David P. ACS Applied Materials & Interfaces, Vol. 10, Issue 42 https://doi.org/10.1021/acsami.8b13031	journal	September 2018
On Low-Concentration Inks Formulated by Nanocellulose Assisted with Gelatin Methacrylate (GelMA) for 3D Printing toward Wound Healing Application Xu, Wenyang; Molino, Binbin Zhang; Cheng, Fang ACS Applied Materials & Interfaces, Vol. 11, Issue 9 https://doi.org/10.1021/acsami.8b21268	journal	February 2019
Interfacial Adhesion of Polylactic Acid on Cellulose Surface: A Molecular Dynamics Study Ren, Zechun; Guo, Rui; Bi, Hongjie ACS Applied Materials & Interfaces, Vol. 12, Issue 2 https://doi.org/10.1021/acsami.9b20101	journal	December 2019
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Wet-Stacking Lamination of Multilayer Mechanically Fibrillated Cellulose Nanofibril (CNF) Sheets with Increased Mechanical Performance for Use in High-Strength and Lightweight Structural and Packaging Applications El Awad Azrak, Sami M.; Clarkson, Caitlyn M.; Moon, Robert J. ACS Applied Polymer Materials, Vol. 1, Issue 9 https://doi.org/10.1021/acsapm.9b00635	journal	August 2019
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Superelastic, Hygroscopic, and Ionic Conducting Cellulose Nanofibril Monoliths by 3D Printing Chen, Yuan; Yu, Zhengyang; Ye, Yuhang ACS Nano, Vol. 15, Issue 1 https://doi.org/10.1021/acsnano.0c10577	journal	January 2021
Dynamics of Cellulose Nanocrystal Alignment during 3D Printing Hausmann, Michael K.; Rühs, Patrick A.; Siqueira, Gilberto ACS Nano, Vol. 12, Issue 7 https://doi.org/10.1021/acsnano.8b02366	journal	June 2018
Polyelectrolyte Complex Coacervate Assembly with Cellulose Nanofibers Khan, Nasreen; Zaragoza, Nadia Z.; Travis, Carly E. ACS Omega, Vol. 5, Issue 28, p. 17129-17140 https://doi.org/10.1021/acsomega.0c00977	journal	July 2020
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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Crystalline and Hairy Nanocelluloses for 3D Printed Hydrogels and Strongly Structured Cryogels Amin Ojagh, Seyed Mohammad; Amini, Majed; Cranmer-Smith, Sierra ACS Sustainable Chemistry & Engineering, Vol. 11, Issue 14 https://doi.org/10.1021/acssuschemeng.3c00180	journal	March 2023
High-Throughput Screening and Accurate Prediction of Ionic Liquid Viscosities Using Interpretable Machine Learning Mohan, Mood; Jetti, Karuna Devi; Guggilam, Sreelekha ACS Sustainable Chemistry & Engineering, Vol. 12, Issue 18 https://doi.org/10.1021/acssuschemeng.4c00631	journal	April 2024
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Enhancing the Mechanical Properties of 3D-Printed Waterborne Polyurethane-Urea and Cellulose Nanocrystal Scaffolds through Crosslinking Vadillo, Julen; Larraza, Izaskun; Calvo-Correas, Tamara Polymers, Vol. 14, Issue 22 https://doi.org/10.3390/polym14224999	journal	November 2022
Poly(lactic acid) and Nanocrystalline Cellulose Methacrylated Particles for Preparation of Cryogelated and 3D-Printed Scaffolds for Tissue Engineering Leonovich, Mariia; Korzhikov-Vlakh, Viktor; Lavrentieva, Antonina Polymers, Vol. 15, Issue 3 https://doi.org/10.3390/polym15030651	journal	January 2023
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