3D Printable Fiber Reinforced bioplastics

Research into renewable and biodegradable alternatives to petroleum-based polymers has seen a sharp increase recently. Yet, few materials resulting from this research have replaced synthetic polymers large-scale consumer product applications. I propose that a possible solution to this issue is to search not for replacements of synthetic polymers, but for renewable biopolymers and composites that afford novel manufacturing, applications, disposal.

In collaboration with Impossible Objects 3D printing, I did an exploratory overview of possible mycelium fiber reinforced chitosan and PHA thermoplastic composites for use in composite-based additive manufacturing (CBAM). Candidate materials were prepared through bacterial fermentation, mechanical evisceration, and CBAM printing for digital microscopy, and degradation. Final candidate composites showed favorable durability and degradability .

Design

Bioplastic designs focused on favorable durability and resilience to fresh water while maintaining rapid decomposition in certain naturally occurring environments. Along with the design of materials, my independent study included speculative design of possible applications and lifecycle for the composites.

Materials

The main materials that I studied for this project were plastics made out of polymers created by decomposers, both fungal and bacterial. polyhydroxyalkanoates, chitosan, thermoplastic starch, and other polymers served as resins into which mycelium, hemp, wool, nanocellulose fiber reinforcements were set.

Fabrication

In collaboration with Impossible Objects 3D printing’s patented CBAM technology to print fiber reinforced thermoplastic composites from my materials suite. The original raw materials were prepared via thermal evisceration in the kitchen of my apartment on the stovetop.

Prototypes

Applications and Lifecycle

Building off of recent findings of the ascomycota aspergillus tubingensis degradation of polyurethanes and polyesters, the use of certain PHA, Chitosan, and thallus-producing decomposers could provide a novel method of both reducing pollution from synthetic polymers as well as producing new materials for use in advanced manufacturing.

Given the extreme scalability of the CBAM printing process in comparison with other 3D printing techniques, I propose that packaging materials and other consumable goods could be replaced with custom-printed fiber reinforced bioplastics made from decomposers. In this way, spent products could easy be composted in farms producing more PHA or Mycelium.

Future development

I am currently pursuing higher fidelity prototypes, growing larger batches of my materials, and filming time-lapse video of their decomposition. Further research and findings will be published as they become available. This project is patent pending.