Periodic Reporting for period 2 - SMART POP (SMART POwder and Products)
Okres sprawozdawczy: 2022-09-11 do 2023-09-10
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.
We selected six different biomasses with contrasting properties (hemp core, pine bark, rice husk, rice husk ash, hibiscus, and spirulina). Ten powders, meeting the specifications for 3D printing, were generated using various technological approaches. Our research primarily aimed to understand how these production methods influenced the powders' properties. Each biomass was thoroughly characterized with the goal of correlating its physical and chemical attributes with their impact on the rheology and processability of the composite materials derived from them.
The research focused on three printing techniques: Paste Printing, Selective Laser Sintering (SLS), and Fused Deposition Modeling (FDM). In line with our goal of minimizing environmental impact, we chose 100% biodegradable matrices such as PHA and natural waxes. This approach leveraged the cutting-edge biotechnological expertise of our host institution, SCION. However, our observations indicated that while Paste Printing showed potential, it lacked efficiency for precision tasks, prompting us to focus more on SLS and FDM.
For SLS, we concentrated on developing a process to produce composite powders for printing, using PHA, natural wax, and vegetable powders. We found that the yield of the SLS powder production process is highly dependent on the properties of the lignocellulosic biomass, though no clear correlation emerged. In an effort to optimize this procedure, we collaborated with the DAGI group (Data and Geospatial Intelligence) at SCION to explore the potential application of machine learning tools for enhancing process parameters, even with a limited dataset. Currently, we have tested various algorithms, with promising results, and further work is ongoing.
Regarding Fused Deposition Modeling, our research highlighted that the properties of lignocellulosic biomass significantly enhance the rheological characteristics and printability of the composite materials. Although the exact parameters responsible for these improvements are not yet fully understood, it appears that lignin content could play a key role in optimizing the printing process.
Finally, the work also demonstrated that mechanosynthesis conducted in a ball mill enables the production of grafted powders with fluorophore and anthocyanin, which can be used as sensors to develop active biobased materials that respond to environmental changes, such as pH variations.
So far, the results have led to five research articles, seven presentations, two patents, and six outreach activities. These outcomes have significantly exceeded the initial plan outlined in the DoA. Three more scientific publications are in preparation, and three presentations are already planned for 2024 and 2025.
The research focused on three printing techniques: Paste Printing, Selective Laser Sintering (SLS), and Fused Deposition Modeling (FDM). In line with our goal of minimizing environmental impact, we chose 100% biodegradable matrices such as PHA and natural waxes. This approach leveraged the cutting-edge biotechnological expertise of our host institution, SCION. However, our observations indicated that while Paste Printing showed potential, it lacked efficiency for precision tasks, prompting us to focus more on SLS and FDM.
For SLS, we concentrated on developing a process to produce composite powders for printing, using PHA, natural wax, and vegetable powders. We found that the yield of the SLS powder production process is highly dependent on the properties of the lignocellulosic biomass, though no clear correlation emerged. In an effort to optimize this procedure, we collaborated with the DAGI group (Data and Geospatial Intelligence) at SCION to explore the potential application of machine learning tools for enhancing process parameters, even with a limited dataset. Currently, we have tested various algorithms, with promising results, and further work is ongoing.
Regarding Fused Deposition Modeling, our research highlighted that the properties of lignocellulosic biomass significantly enhance the rheological characteristics and printability of the composite materials. Although the exact parameters responsible for these improvements are not yet fully understood, it appears that lignin content could play a key role in optimizing the printing process.
Finally, the work also demonstrated that mechanosynthesis conducted in a ball mill enables the production of grafted powders with fluorophore and anthocyanin, which can be used as sensors to develop active biobased materials that respond to environmental changes, such as pH variations.
So far, the results have led to five research articles, seven presentations, two patents, and six outreach activities. These outcomes have significantly exceeded the initial plan outlined in the DoA. Three more scientific publications are in preparation, and three presentations are already planned for 2024 and 2025.
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 for her to be trained 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 master’s students (7 in total) working on this project, both at the host institution and in the partner laboratories involved in the project. She was supervised 2 visitor PhD student at SCION for 2 and 4 months respectively. The career progression made during the outgoing phase allowed Dr. Claire Mayer-Laigle to refocus her activities on research after a period where she was more involved in managing a research structure. This also led to her obtaining the 'Habilitation à Diriger les Recherches' in 2022, a French qualification that certifies the capability to independently supervise doctoral students. Moreover, her prior managerial experience was leveraged to set up and coordinate an international associated laboratory, greatly expanding the original project’s scope. Finally, upon her return to France, Dr. Claire Mayer-Laigle was also promoted to Research Director in January 2024 after successfully competing for the position, marking a significant advancement in her career.
In terms of impact on the socio-economic world, the project also led to patentable results (2 patents). 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 for her to be trained 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 master’s students (7 in total) working on this project, both at the host institution and in the partner laboratories involved in the project. She was supervised 2 visitor PhD student at SCION for 2 and 4 months respectively. The career progression made during the outgoing phase allowed Dr. Claire Mayer-Laigle to refocus her activities on research after a period where she was more involved in managing a research structure. This also led to her obtaining the 'Habilitation à Diriger les Recherches' in 2022, a French qualification that certifies the capability to independently supervise doctoral students. Moreover, her prior managerial experience was leveraged to set up and coordinate an international associated laboratory, greatly expanding the original project’s scope. Finally, upon her return to France, Dr. Claire Mayer-Laigle was also promoted to Research Director in January 2024 after successfully competing for the position, marking a significant advancement in her career.
In terms of impact on the socio-economic world, the project also led to patentable results (2 patents). 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.