3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability
This study explores development and 3D/4D printing of environmentally friendly bio-composites with enhanced mechanical properties, flame retardancy, and shape memory capabilities. Composite filaments were created by incorporating polylactic acid (PLA) with bamboo charcoal (BC) and then printed using...
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| Language: | English |
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Elsevier
2025-02-01
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| Series: | Polymer Testing |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0142941825000236 |
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| author | Mahdi Bodaghi Kaveh Rahmani Mohammadreza Lalegani Dezaki Callum Branfoot Jon Baxendale |
| author_facet | Mahdi Bodaghi Kaveh Rahmani Mohammadreza Lalegani Dezaki Callum Branfoot Jon Baxendale |
| author_sort | Mahdi Bodaghi |
| collection | DOAJ |
| description | This study explores development and 3D/4D printing of environmentally friendly bio-composites with enhanced mechanical properties, flame retardancy, and shape memory capabilities. Composite filaments were created by incorporating polylactic acid (PLA) with bamboo charcoal (BC) and then printed using a modified printer equipped with a dual-feed system to accommodate both PLA/BC filaments and continuous flax fibres (CFF). SEM revealed strong fibre-matrix bonding with minimal voids, indicating good interfacial adhesion. Bio-composite properties were characterised through DMA, tensile, three-point bending, flammability, and shape-memory effect tests. Adding 3 wt% BC and CFF significantly increased the tensile strength by 248 % and the flexural strength by 207 % compared to pure PLA. Flame retardancy properties were notably improved, with a 50 % reduction in the burning rate, and underwriters’ laboratories (UL-94) rate and limiting oxygen index (LOI) reached to V-1 rating and 36.8%vol, respectively. DMA tests showed an increase in storage modulus, indicating improved stiffness. Shape memory tests under cold/hot programming protocols demonstrated efficient shape fixation with shape recovery ratios reaching up to 98.9 % for pure PLA and 89 % for PLA/BC/CFF for hot programming. Finally, a conceptual meta-bio-composite was 4D printed, showcasing key achievements such as quasi-zero stiffness, constant force behaviour, enhanced energy absorption/dissipation, and excellent recoverability and reusability. This highlights their potential for applications requiring durability, safety, comfort, and sustainability in sectors such as automotive, aerospace, logistics, construction, and furniture. |
| format | Article |
| id | doaj-art-bdb40e79d3c14bd0bc7c1602f872986b |
| institution | Kabale University |
| issn | 1873-2348 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Polymer Testing |
| spelling | doaj-art-bdb40e79d3c14bd0bc7c1602f872986b2025-01-23T05:25:25ZengElsevierPolymer Testing1873-23482025-02-011431087093D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverabilityMahdi Bodaghi0Kaveh Rahmani1Mohammadreza Lalegani Dezaki2Callum Branfoot3Jon Baxendale4Department of Engineering, School of Science and Technology, Nottingham Trent University, Nottingham, NG11 8NS, UK; Corresponding author.Department of Engineering, School of Science and Technology, Nottingham Trent University, Nottingham, NG11 8NS, UKDepartment of Engineering, School of Science and Technology, Nottingham Trent University, Nottingham, NG11 8NS, UKEngineering Operations, National Composites Centre, Bristol, BS16 7FS, UKEngineering Operations, National Composites Centre, Bristol, BS16 7FS, UKThis study explores development and 3D/4D printing of environmentally friendly bio-composites with enhanced mechanical properties, flame retardancy, and shape memory capabilities. Composite filaments were created by incorporating polylactic acid (PLA) with bamboo charcoal (BC) and then printed using a modified printer equipped with a dual-feed system to accommodate both PLA/BC filaments and continuous flax fibres (CFF). SEM revealed strong fibre-matrix bonding with minimal voids, indicating good interfacial adhesion. Bio-composite properties were characterised through DMA, tensile, three-point bending, flammability, and shape-memory effect tests. Adding 3 wt% BC and CFF significantly increased the tensile strength by 248 % and the flexural strength by 207 % compared to pure PLA. Flame retardancy properties were notably improved, with a 50 % reduction in the burning rate, and underwriters’ laboratories (UL-94) rate and limiting oxygen index (LOI) reached to V-1 rating and 36.8%vol, respectively. DMA tests showed an increase in storage modulus, indicating improved stiffness. Shape memory tests under cold/hot programming protocols demonstrated efficient shape fixation with shape recovery ratios reaching up to 98.9 % for pure PLA and 89 % for PLA/BC/CFF for hot programming. Finally, a conceptual meta-bio-composite was 4D printed, showcasing key achievements such as quasi-zero stiffness, constant force behaviour, enhanced energy absorption/dissipation, and excellent recoverability and reusability. This highlights their potential for applications requiring durability, safety, comfort, and sustainability in sectors such as automotive, aerospace, logistics, construction, and furniture.http://www.sciencedirect.com/science/article/pii/S0142941825000236Continuous flax fibreBamboo charcoalShape memory polymerMeta-bio-compositeFlame retardancy3D/4D printing |
| spellingShingle | Mahdi Bodaghi Kaveh Rahmani Mohammadreza Lalegani Dezaki Callum Branfoot Jon Baxendale 3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability Polymer Testing Continuous flax fibre Bamboo charcoal Shape memory polymer Meta-bio-composite Flame retardancy 3D/4D printing |
| title | 3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability |
| title_full | 3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability |
| title_fullStr | 3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability |
| title_full_unstemmed | 3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability |
| title_short | 3D/4D printed bio-composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength, flame retardancy and recoverability |
| title_sort | 3d 4d printed bio composites reinforced by bamboo charcoal and continuous flax fibres for superior mechanical strength flame retardancy and recoverability |
| topic | Continuous flax fibre Bamboo charcoal Shape memory polymer Meta-bio-composite Flame retardancy 3D/4D printing |
| url | http://www.sciencedirect.com/science/article/pii/S0142941825000236 |
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