Large-scale additive manufacturing materials comprising pyrolyzed lignocellulosic filler
A material including (i) a polymer matrix and (ii) a pyrolyzed lignocellulosic filler dispersed in the polymer matrix, for large-scale additive manufacturing.
1 . A method for forming an additive manufacturing material, the method comprising:
(a) providing a pyrolyzed lignocellulosic filler pyrolyzed at a temperature of from 220 to 500° C.; and
(b) compounding the pyrolyzed lignocellulosic filler with a polymer matrix and optional additives;
wherein the pyrolyzed lignocellulosic filler has an average particle size between 20 and 500 μm.
2 . The method according to claim 1 , wherein step b comprises compounding from 0.1 to 65 wt % of the pyrolyzed lignocellulosic filler with the polymer matrix and optional additives.
3 . The method according to claim 1 , wherein step a comprises:
(a1) pyrolyzing a lignocellulosic biomass.
4 . The method according to claim 3 , wherein pyrolyzing the lignocellulosic biomass is performed at a temperature of from 220 to 400° C.
5 . The method according to claim 3 , wherein the lignocellulosic biomass is selected from wood, flax and bamboo.
6 . The method according to claim 3 , wherein step a further comprises:
(a2) grinding the pyrolyzed lignocellulosic biomass to obtain the pyrolyzed lignocellulosic filler.
7 . A method for forming a product by additive manufacturing of an additive manufacturing material, comprising
(i) a polymer matrix and
(ii) a pyrolyzed lignocellulosic filler dispersed in the polymer matrix, the pyrolyzed lignocellulosic filler being pyrolyzed at a temperature of from 220 to 500° C. and having an average particle size between 20 and 500 μm,
the method comprising:
(a) feeding the additive manufacturing material into an additive manufacturing system, and
(b) printing the product using the additive manufacturing system.
8 . The method according to claim 1 , wherein the pyrolyzed lignocellulosic filler is a torrefied or charred lignocellulosic filler.
9 . The method according to claim 1 , wherein the polymer matrix is selected from a thermoplastic polymer or thermosetting polymer.
10 . The method according to claim 7 , wherein the additive manufacturing system is a granular material-based additive manufacturing system.
11 . The method according to claim 7 , wherein the product is printed having at least one dimension of 1 m or larger.