Could Cellulose Fibers Be Used As Reinforcement Material for Composite 3D Printing?

The German Institute of Textile and Fiber Research recently launched a research project to develop an innovative 3D printing method for composite materials. The goal is to produce components reinforced with bio-based and sustainable fibers such as cellulose fibers. The project team has collaborated with machine manufacturer Arburg to develop a print head that can extrude continuous cellulose fibers embedded in a cellulose-based matrix. The project, funded by Germany’s Federal Ministry of Education and Research, would make it possible to draw on a material that is very abundant today and design more durable parts that take full advantage of composite 3D printing.

The research project is an example of how we can take inspiration from nature and combine it with additive manufacturing. In our case, we are talking about additive manufacturing with composites. Without perhaps knowing it, we are surrounded by composites: Wood, plants, spider silk, or even skin. These natural fibers offer very interesting properties, whether in terms of strength or even lightness. So why not use them for 3D printing?

Cellulose fibers produced by pultrusion ( a portmanteau of pull and extrusion; as opposed to extrusion, which pushes the material, pultrusion pulls the material)

The biggest challenge is temperature management. This is because natural fibers – such as cellulose fibers – are very sensitive to high temperatures, which precludes the possibility of working with a PLA- or ABS-type plastic matrix, since the thermoplastic must be heated sufficiently to be applied layer by layer. So the team had to think of both a new matrix and a 3D printing process with the cellulose that would meet those temperature constraints.