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The new 3D printing process of continuous cellulose fiber composites

Cellulose fibers were pultruded with a cellulose-based binder. Photo: DITF
Newly developed print head for 3D printing of continuous cellulose fiber-reinforced components. Photo. DITF
3D-Printed continuous fiber reinforced test coupon. Photo: DITF

The German Institutes of Textile and Fibre Research (DITF), together with Arburg GmbH + Co KG, are developing an energy- and material-efficient 3D printing process for manufacturing of lightweight bio-based fibre composites. An article posted on DIFT website describe the process:

Nature works often with fibre composites. The construction principles of nature require little material and energy and thus ensure the survival of animals and plant species. Examples include wood, plant stalks, chitinous shells, bones, or tissues such as tendons and skin. Mussel shells or spider silk are also composite tissues. We can take advantage of these principles to design and manufacture bio-based, sustainable fibre reinforced composites, which are currently in high demand. Bio-based fibre reinforced composites consist of natural fibres or cellulose fibres embedded in a bio-based matrix. The bio-based components offer properties comparable to those of commonly used glass fibre composites.

In fibre composites, which occur naturally, reinforcing fibers such as collagen or cellulose fibrils are embedded in a matrix of lignin, hemicellulose or collagen. The fibre strands align with the stress patterns. Tissues are formed mostly via solution-based physio-chemical processes that take place at ambient temperature. Similar to nature, new 3D printing processes with continuous fibre reinforcement also allow the deposition of fibre strands in the right place (topology optimization) and in the appropriate direction in accordance to the load. However, natural fibers such as cellulose fibres are sensitive to higher temperatures. Therefore, they cannot be processed in the commonly employed thermoplastic 3D printing process.

The result of the research work is 3D-printed fibre composite components consisting of cellulose continuous fibers embedded in a cellulose-based matrix. Newly developed 3D-printing process enables to manufacture the composites at ambient temperature. This means that – as in nature – the material and component can be produced simultaneously in a single operation at ambient temperature.

The cellulose fiber strand is first stabilized with a binder for processing in the printer. The specially designed print head transforms the binder into a matrix with which the cellulose continuous fibers are encased. Since the cellulose fibers and the matrix have similar chemical structures, the composite component is particularly stable. The mechanical properties, such as breaking strength, are exceptionally good. The solution-based and energy-efficient manufacturing method developed by the research team can also be used in other composite materials manufacturing processes. It is particularly suitable for processing temperature-sensitive materials that are in high demand, such as natural or cellulose fibers.

The ” CellLoes-3D-Druck” research project is funded by the German Federal Ministry of Education and Research as part of the “Biologisierung der Technik” ideas competition.

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