Periodic Reporting for period 1 - SMART POP (SMART POwder and Products)
Période du rapport: 2020-11-11 au 2022-09-10
The current lifestyles of the EU, New Zealand, and other emerging countries, along with their technological advancements, have led to societal expectations for the design of new hi-tech products. In recent years, the use of cellulose and lignocellulosic materials for chemistry, energy, and materials has emerged as a sustainable alternative to fossil feedstock. However, research must be conducted to develop efficient processes that can economically and competitively produce high-value products from plant feedstocks.
The SMART POP project aims to address this need by designing new environmentally-friendly materials from biobased matrices and lignocellulosic biomass powder, particularly by employing mechanosynthesis and additive manufacturing techniques. The project's objective is to analyze how the properties of powders resulting from the mechanical deconstruction of lignocellulosic biomasses can influence the performance of the composite biobased materials created through 3D printing.
To achieve this, the project employs a dual strategy based on both direct and reverse engineering at different stages of the manufacturing process. Direct engineering is used to understand how feedstock properties and process parameters affect the qualities of powders and end products. In parallel, a reverse engineering approach is implemented to adjust the properties of the 3D printed products by modifying the process conditions during milling and additive manufacturing.
The SMART POP project aims to address this need by designing new environmentally-friendly materials from biobased matrices and lignocellulosic biomass powder, particularly by employing mechanosynthesis and additive manufacturing techniques. The project's objective is to analyze how the properties of powders resulting from the mechanical deconstruction of lignocellulosic biomasses can influence the performance of the composite biobased materials created through 3D printing.
To achieve this, the project employs a dual strategy based on both direct and reverse engineering at different stages of the manufacturing process. Direct engineering is used to understand how feedstock properties and process parameters affect the qualities of powders and end products. In parallel, a reverse engineering approach is implemented to adjust the properties of the 3D printed products by modifying the process conditions during milling and additive manufacturing.
During the reporting period, we selected six different biomasses with contrasting properties (Hemp Core, Pine bark, Rice Husk, Rice Husk Ash, Hibiscus, and Spirulina). Ten powders with specifications aligned with 3D printing requirements were generated using various technological routes. Our research primarily aimed to understand how these production pathways influenced the powders' properties. Each biomass was comprehensively characterized with the intent to correlate its physical and chemical attributes with their impact on the rheological and processability of composite materials derived from them.
The research work primarily focused on three printing techniques: Paste Printing, Selective Laser Sintering (SLS), and Fused Deposition Modeling (FDM). In our pursuit of minimal environmental impact, we opted for 100% biodegradable matrices, such as PHA and natural waxes. This approach benefited from the cutting-edge biotechnological advancements and expertise of our hosting institution, SCION. However, our observations indicated that while Paste Printing showed potential, it lacked efficiency for precision tasks, leading us to shift our focus more towards SLS and FDM.
In the context of SLS, our work focused on developing a process to produce composite powders for printing, derived from PHA, natural wax, and vegetable powders. However, we also determined that the yield of the SLS powder production process is highly contingent upon the properties of the lignocellulosic biomass, although no evident correlation emerged. In an effort to optimize this procedure, we collaborated with the DAGI group (Data and Geospatial Intelligence) at SCION to investigate the potential application of machine learning tools for enhancing process parameters, even when working with a limited dataset. Currently, we have tested various algorithms, and the results appear promising. Further works are in progress.
Regarding Fused Deposition Modeling, our research underscored that the properties of the lignocellulosic biomass significantly enhance the rheological attributes and printability of the composite materials. Although the precise parameters responsible for these improvements remain not fully understood, it appears that the lignin content could be a key parameter in optimizing the printing process.
So far, the results obtained have led to one patent and one invention disclosure, as well as three scientific publications and seven presentations at international conferences. These outcomes exceeded what had been initially planned in the DoA.
The research work primarily focused on three printing techniques: Paste Printing, Selective Laser Sintering (SLS), and Fused Deposition Modeling (FDM). In our pursuit of minimal environmental impact, we opted for 100% biodegradable matrices, such as PHA and natural waxes. This approach benefited from the cutting-edge biotechnological advancements and expertise of our hosting institution, SCION. However, our observations indicated that while Paste Printing showed potential, it lacked efficiency for precision tasks, leading us to shift our focus more towards SLS and FDM.
In the context of SLS, our work focused on developing a process to produce composite powders for printing, derived from PHA, natural wax, and vegetable powders. However, we also determined that the yield of the SLS powder production process is highly contingent upon the properties of the lignocellulosic biomass, although no evident correlation emerged. In an effort to optimize this procedure, we collaborated with the DAGI group (Data and Geospatial Intelligence) at SCION to investigate the potential application of machine learning tools for enhancing process parameters, even when working with a limited dataset. Currently, we have tested various algorithms, and the results appear promising. Further works are in progress.
Regarding Fused Deposition Modeling, our research underscored that the properties of the lignocellulosic biomass significantly enhance the rheological attributes and printability of the composite materials. Although the precise parameters responsible for these improvements remain not fully understood, it appears that the lignin content could be a key parameter in optimizing the printing process.
So far, the results obtained have led to one patent and one invention disclosure, as well as three scientific publications and seven presentations at international conferences. These outcomes exceeded what had been initially planned in the DoA.
The SMARTPOP Project explores a research sector in which little had been done before. The combination of skills from both institutions led to innovative results that have been shared within the scientific community through publications and oral presentations. Several more publications are also planned. Additionally, the SMARTPOP Project enables the establishment of an International associated lab (LIA BIOMATA), which represents a significant gateway for the scientific community. Building a strong network around these research themes was indeed one of the objectives listed in the DoA.
In terms of impact on the researchers' careers, Dr. Claire Mayer-Laigle was trained in numerous techniques, whether in characterization or additive manufacturing, directly within the institute or through developed collaborations. Dr. Claire Mayer-Laigle also had the opportunity to participate in an experimental campaign at the Melbourne Synchrotron on the Small and Wide Angle X-ray Scattering beamline (X-ray Diffraction) to characterize plant powders. This experience provided an opportunity to train in new techniques and to develop specific advancements. All of this support contributed to the success of the outgoing phase and the creation of the aforementioned LIA BIOMATA. During this period, Dr. Claire Mayer-Laigle also supervised several students (8 in total) working on this project, both within the hosting institution and the partner laboratories involved in the project. This also led her to obtain the "Habilitation à Diriger les Recherches" in 2022, a French qualification that certifies the capability to independently supervise doctoral students.
In terms of impact on the socio-economic world, the project also led to patentable results (1 patent and an invention disclosure currently under review). These results have been the subject of a technological offer publication to seek industrial partners for the development of our technology. The offer has caught the attention of several industrial companies. In collaboration with a dedicated support team at INRAE, we are currently considering the formation of a consortium of non-competing industrial companies that could invest in a research project and help push its development forward.
In terms of impact on the researchers' careers, Dr. Claire Mayer-Laigle was trained in numerous techniques, whether in characterization or additive manufacturing, directly within the institute or through developed collaborations. Dr. Claire Mayer-Laigle also had the opportunity to participate in an experimental campaign at the Melbourne Synchrotron on the Small and Wide Angle X-ray Scattering beamline (X-ray Diffraction) to characterize plant powders. This experience provided an opportunity to train in new techniques and to develop specific advancements. All of this support contributed to the success of the outgoing phase and the creation of the aforementioned LIA BIOMATA. During this period, Dr. Claire Mayer-Laigle also supervised several students (8 in total) working on this project, both within the hosting institution and the partner laboratories involved in the project. This also led her to obtain the "Habilitation à Diriger les Recherches" in 2022, a French qualification that certifies the capability to independently supervise doctoral students.
In terms of impact on the socio-economic world, the project also led to patentable results (1 patent and an invention disclosure currently under review). These results have been the subject of a technological offer publication to seek industrial partners for the development of our technology. The offer has caught the attention of several industrial companies. In collaboration with a dedicated support team at INRAE, we are currently considering the formation of a consortium of non-competing industrial companies that could invest in a research project and help push its development forward.