Integrated Natural Fibre Printing with Lignin Ink and Ultrasonic Welding for On-the-Go Consolidation

Objetivo

In my ERC Consolidator project (AM-IMATE), I explore embedding the adaptive capabilities of living systems into materials, using mycelium as a biological binder to consolidate wood-based lattice assemblies. Building on this, our research on ultrasonic welding of wood demonstrates that lignin can be formulated into a printable, energy-directing ink to achieve rapid, strong, and resin-free bonding. However, a fundamental manufacturing bottleneck persists: the consolidation of natural fibre composites remains a decoupled process requiring petroleum-based resins and heated curing, introducing energy penalties and rendering the structures non-recyclable.

Our Proof of Concept, FIBREWELD, addresses this by integrating natural fibre 3D printing, lignin-based bio-ink deposition, and ultrasonic welding into a single robotic manufacturing head for real-time consolidation. This resin-free platform enables the production of fully recyclable, lightweight composite structures, such as honeycombs and lattices, with embedded sensing capabilities and mechanical properties comparable to those of conventional composites. Targeting applications in sustainable architecture, automotive interiors, and aerospace, this project establishes a zero-waste, bio-based manufacturing paradigm and secures clear pathways to commercialisation through industry validation.

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