Lignin model compounds as bio-based reactive diluents for liquid molding resins

Lignin: A multi-faceted role/function in 3D printing inks

3D printing technology demonstrates significant potential for the rapid fabrication of tailored geometric structures. Nevertheless, the prevalent use of fossil-derived compositions in printable inks within the realm of 3D printing results in considerable environmental pollution and ecological consequences. Lignin, the second most abundant biomass source on earth, possesses attributes such as cost-effectiveness, renewability, biodegradability, and non-toxicity. Enriched with active functional groups including hydroxyl, carbonyl, carboxyl, and methyl, coupled with its rigid aromatic ring structure and inherent anti-oxidative and thermoplastic properties, lignin emerges as a promising candidate for formulating printable inks. This comprehensive review presents the utilization of lignin, either in conjunction with functional materials or through the modification of lignin derivatives, as the primary constituent (≥50 wt%) for formulating printable inks across photo-curing-based (SLA/DLP) and extrusion-based (DIW/FDM) printing technologies. Furthermore, lignin as an additive with multi-faceted roles/functions in 3D printing inks is explored. The effects of lignin on the properties of printing inks and printed objects are evaluated. Finally, this review outlines future perspectives, emphasizing key obstacles and potential opportunities for facilitating the high-value utilization of lignin in the realm of 3D printing.

Recent advances in lignin-based 3D printing materials: A mini-review

With the growing global population and rapid economic development, the demand for energy and raw materials is increasing, and the supply of fossil resources as the main source of energy and raw materials has reached a critical juncture. However, our overexploitation and overconsumption of fossil resources have led to serious problems, including environmental pollution, climate change, and ecosystem destruction. In the face of these challenges, we must recognize the negative impacts of the shortage of fossil resources and actively seek sustainable alternative sources of energy and resources to protect our environment and sustainable development in the future. Three-dimensional (3D) printing, an additive manufacturing technology, has been used in many fields to manufacture complex and high-precision products. While traditional manufacturing processes typically produce large amounts of waste and emissions that are harmful to the environment, 3D printing is much more energy efficient compared to traditional manufacturing methods, which helps to lower energy costs and reduce reliance on non-renewable energy sources. The development of low-carbon and environmentally friendly 3D printing materials can help to reduce carbon emissions and environmental pollution and realize the goal of sustainable development. Lignin, as the second largest renewable green biomass resource after cellulose, has great potential for manufacturing low-carbon and environmentally friendly 3D printing materials. This review presents some recent studies on the applications of lignin and its derivatives in photo-curing 3D printing, including the preparation and performance of lignin-based photosensitive prepolymers, lignin-based reactive diluents, lignin-based photo-initiators, and lignin-based additive. This review also provides recent studies on the preparation and performance of lignin-based thermoplastic polymer for Fused Deposition Modeling (FDM) 3D printing. Finally, the future challenges and industrialization prospects of lignin-based 3D printing materials are discussed.

Fully bio-based and intrinsically flame retardant unsaturated polyester cross-linked with isosorbide-based diluents

Unsaturated polyester resins (UPR) are composed of prepolymers and styrene diluents, while the former are produced by co-polycondensation between diol, unsaturated diacid and saturated diacid. In this work, bio-based UPR prepolymers were synthesized from bio-based oxalic acid, itaconic acid, and ethylene glycol, which were then diluted with bio-based isosorbide methacrylate (MI). Meanwhile, the phenylphosphonate were introduced into the molecular chains of prepolymers to achieve intrinsic flame retardancy of bio-based UPR. The potential of the reactive MI diluents as substitutes of volatile styrene, was also assessed through the volatility test, curing kinetics and gel contents analysis. For UPR materials with styrene diluents, the UPR materials can achieve UL-94 V0 level and the 28% of limiting oxygen index (LOI) with 2.63 wt% of phosphorus contents. By contrast, the UPR materials with MI diluents can reach UL-94 V0 level with only 2.14 wt% of phosphorus contents. As the phosphorus contents were further increased to 2.63 wt%, UPR materials can achieve highest 29%, while the peak of heat release rate (PHRR) and total heat release (THR) were decreased by 68.01% and 48.62%, respectively. The Flame Retardancy Index (FRI) was also used to comprehensively evaluate the flame retardant performance of UPR composites. Compared with neat UPR, the composites with MI diluents and phosphorus containing structures increased from 1.00 to 6.46. The mechanism for improved flame retardancy was analyzed from gaseous and condensed phase. Additionally, the tensile strengths of bio-based UPR materials with styrene and MI diluents were studied. This work provides an effective method to prepared high-performance and fully bio-based UPR materials with improved flame retardant properties and safety application of reactive diluents.

Polymers without Petrochemicals: Sustainable Routes to Conventional Monomers

Access to a wide range of plastic materials has been rationalized by the increased demand from growing populations and the development of high-throughput production systems. Plastic materials at low costs with reliable properties have been utilized in many everyday products. Multibillion-dollar companies are established around these plastic materials, and each polymer takes years to optimize, secure intellectual property, comply with the regulatory bodies such as the Registration, Evaluation, Authorisation and Restriction of Chemicals and the Environmental Protection Agency and develop consumer confidence. Therefore, developing a fully sustainable new plastic material with even a slightly different chemical structure is a costly and long process. Hence, the production of the common plastic materials with exactly the same chemical structures that does not require any new registration processes better reflects the reality of how to address the critical future of sustainable plastics. In this review, we have highlighted the very recent examples on the synthesis of common monomers using chemicals from sustainable feedstocks that can be used as a like-for-like substitute to prepare conventional petrochemical-free thermoplastics.

Functional Lignin Building Blocks: Reactive Vinyl Esters with Acrylic Acid

Introducing vinyl groups onto the backbone of technical lignin provides an opportunity to create highly reactive renewable polymers suitable for radical polymerization. In this work, the chemical modification of softwood kraft lignin was pursued with etherification, followed by direct esterification with acrylic acid (AA). In the first step, phenolic hydroxyl and carboxylic acid groups were derivatized into aliphatic hydroxyl groups using ethylene carbonate and an alkaline catalyst. The lignin was subsequently fractionated using a downward precipitation method to recover lignin of defined molar mass and solubility. After recovery, the resulting material was then esterified with AA, resulting in lignin with vinyl functional groups. The first step resulted in approximately 90% of phenolic hydroxyl groups being converted into aliphatic hydroxyls, while the downward fractionation resulted in three samples of lignin with defined molar masses. For the esterification reaction, the weight ratio of reagents, reaction temperature, and reaction time were evaluated as factors that would influence the modification efficacy. ¹³C NMR spectroscopy analysis of lignin samples before and after esterification showed that the optimized reaction conditions could reach approximately 40% substitution of aliphatic hydroxyl groups. Both steps only used lignin and the modifying reagent (no solvent), with the possibility of recovery and reuse of the reagent by dilution and distillation. An additional second esterification step of the resulting lignin sample with acetic acid or propionic acid converted 90% of remaining hydroxyl groups into short-chain carbon aliphatic esters, making a hydrophobic material suitable for further copolymerization with synthetic hydrophobic monomers.

The Effect of Glycol Derivatives on the Properties of Bio-Based Unsaturated Polyesters

The scope of the present study was to prepare fully bio-based unsaturated polyester resins (UPRs) with comparable properties to the commercial formulations. The focus was set on the determination of the optimal prepolymer formulation using the same set of diacids (itaconic and succinic acid) and different diols (propylene glycol, isosorbide and neopentyl glycol) or its equimolar mixtures, keeping the fixed molar ratio of 1:1:2.1 in all feed compositions. Instead of commonly used styrene, bio-based dimethyl itaconate was used as a reactive diluent (RD). The rheology of the obtained resins was studied in detail. The effect of the used diol on structural (FTIR), thermal (DSC), thermomechanical (DMA), and mechanical (tensile) properties was explained. The properties of UPRs were found to be highly dependent on the diol used in the prepolymer formulation. The UPR with an equimolar ratio of propylene glycol and neopentyl glycol was shown to be the most promising candidate to compete with the commercial petroleum-based resins.

Ambient-pressure lignin valorization to high-performance polymers by intensified reductive catalytic deconstruction

Chemocatalytic lignin valorization strategies are critical for a sustainable bioeconomy, as lignin, especially technical lignin, is one of the most available and underutilized aromatic feedstocks. Here, we provide the first report of an intensified reactive distillation–reductive catalytic deconstruction (RD-RCD) process to concurrently deconstruct technical lignins from diverse sources and purify the aromatic products at ambient pressure. We demonstrate the utility of RD-RCD bio-oils in high-performance additive manufacturing via stereolithography 3D printing and highlight its economic advantages over a conventional reductive catalytic fractionation/RCD process. As an example, our RD-RCD reduces the cost of producing a biobased pressure-sensitive adhesive from softwood Kraft lignin by up to 60% in comparison to the high-pressure RCD approach. Last, a facile screening method was developed to predict deconstruction yields using easy-to-obtain thermal decomposition data. This work presents an integrated lignin valorization approach for upgrading existing lignin streams toward the realization of economically viable biorefineries.

Lignin-Inspired Polymers with High Glass Transition Temperature and Solvent Resistance from 4-Hydroxybenzonitrile, Vanillonitrile, and Syringonitrile Methacrylates

We here report on the synthesis and polymerization of nitrile-containing methacrylate monomers, prepared via straightforward nitrilation of the corresponding lignin-inspired aldehyde. The polymethacrylates reached exceptionally high glass transition temperatures (T _g values), i.e., 150, 164, and 238 °C for the 4-hydroxybenzonitrile, vanillonitrile, and syringonitrile derivatives, respectively, and were thermally stable up to above 300 °C. Copolymerizations of the nitrile monomers with styrene and methyl methacrylate, respectively, gave potentially melt processable materials with tunable T _g values and enhanced solvent resistance. The use of lignin-derived nitrile-containing monomers represents an efficient strategy toward well-defined biobased high T _g polymer materials.

Wood-Mimicking Bio-Based Biporous Polymeric Materials with Anisotropic Tubular Macropores

Understanding physical phenomena related to fluid flow transport in plants and especially through wood is still a major challenge for the scientific community. To this end, we have focused our attention on the design of wood-mimicking polymeric architectures through a strategy based on the double porogen templating approach which relies on the use of two distinct types of porogens, namely aligned nylon threads and a porogenic solvent, to produce macro- and nanoporosity levels, respectively. A bio-based phenolic functional monomer, i.e., vanillin methacrylate, was employed to mimic either hard wood or soft wood. Upon free-radical polymerization with a crosslinking agent in the presence of both types of porogenic agents, followed by their removal, biporous materials with anistotropic tubular macropores surrounded by a nanoporous matrix were obtained. They were further fully characterized in terms of porosity and chemical composition via mercury intrusion porosimetry, scanning electron microscopy and X-ray microtomography. It was demonstrated that the two porosity levels could be independently tuned by varying structural parameters. Further, the possibility to chemically modify the pore surface and thus to vary the material surface properties was successfully demonstrated by reductive amination with model compounds via Raman spectroscopy and water contact angle measurements.

Building biobased, degradable, flexible polymer networks from vanillin via thiol–ene “click” photopolymerization

A new biobased allyl ether monomer with acetal groups is synthesized from renewable vanillin for building flexible transparent thiol–ene networks with good degradability under mild acidic conditions.

Ethyl cellulose based self-healing adhesives synthesized via RAFT and aromatic schiff-base chemistry

In this work, reversible addition-fragmentation chain transfer (RAFT) polymerization and Schiff base chemistry was combined to fabricate self-healing adhesives. An esterification reaction was first performed to prepare ethyl cellulose based macroinitiators. Then, a "grafting from" RAFT of vanillin methacrylate and lauryl methacrylate was used to obtain graft copolymers. DSC result showed that the glass transition temperature was manipulated via changing the ratio of vanillin and fatty acids moieties. NMR spectrum analysis demonstrated the presence of aldehyde groups, which were available for the dynamic crosslinking to generate a network as self-healing adhesives. The adhesive test showed that the shear strength could reach 0.81 MPa with a self-healing efficiency of 98.7 %. The bottlebrush structures of copolymers and reversibility of Schiff base chemistry might collaboratively contribute to the high self-healing efficiency. This study provides a facile way to fabricate high-performance self-healing adhesives from ethyl cellulose and renewable resources.

100th Anniversary of Macromolecular Science Viewpoint: Polymers from Lignocellulosic Biomass. Current Challenges and Future Opportunities

Sustainable polymers from lignocellulosic biomass have the potential to reduce the environmental impact of commercial plastics while also offering significant performance and cost benefits relative to petrochemical-derived macromolecules. However, most currently available biobased polymers are hampered by insufficient thermomechanical properties, low economic feasibility (e.g., high relative cost), and reduced scalability in comparison to petroleum-based incumbents. Future biobased materials must overcome these limitations to be competitive in the marketplace. Additionally, sustainability challenges at the beginning and end of the polymer lifecycle need to be addressed using green chemistry practices and improved end-of-life waste management strategies. This viewpoint provides an overview of recent developments that can mitigate many concerns with present materials and discusses key aspects of next-generation, biobased polymers derived from lignocellulosic biomass.

Synthesis and polymerization of bio-based acrylates: a review

Acrylates and polyacrylates have been produced massively due to their interesting applications like Plexiglas.

A Review on Styrene Substitutes in Thermosets and Their Composites

In recent decades, tremendous interest and technological development have been poured into thermosets and their composites. The thermosets and composites with unsaturated double bonds curing system are especially concerned due to their versatility. To further exploit such resins, reactive diluents (RDs) with unsaturated sites are usually incorporated to improve their processability and mechanical properties. Traditional RD, styrene, is a toxic volatile organic compound and one of the anticipated carcinogens warned by the National Institute of Health, USA. Most efforts have been conducted on reducing the usage of styrene in the production of thermosets and their composites, while very few works have systematically summarized these literatures. Herein, recent developments regarding styrene substitutes in thermosets and their composites are reviewed. Potential styrene alternatives, such as vinyl derivatives of benzene and (methyl)acrylates are discussed in details. Emphasis is focused on the strategies on developing novel RD monomers through grafting unsaturated functional groups on renewable feedstocks such as carbohydrates, lignin, and fatty acids. This review also highlights the development and characteristics of RD monomers and their influence on processability and mechanical performance of the resulting thermosets and composites.

Fast pyrolysis bio-oil from lignocellulosic biomass for the development of bio-based cyanate esters and cross-linked networks

Fast pyrolysis of pine wood was carried out to yield a liquid bio-oil mixture that was separated into organic and aqueous phases. The organic phase (ORG-bio-oil) was characterized by gas chromatography–mass spectroscopy, 31P-nuclear magnetic resonance spectroscopy, and Fourier transform infrared (FTIR) spectroscopy. It was further used as a raw material for producing a mixture of biphenolic compounds (ORG-biphenol). ORG-bio-oil, ORG-biphenol, and bisphenol-A were reacted with cyanogen bromide to yield cyanate ester monomers. Cyanate esters were characterized using FTIR spectroscopy and were thermally cross-linked to develop thermoset materials. Thermomechanical properties of cross-linked cyanate esters were assessed using dynamic mechanical analysis and compared with those of cross-linked bisphenol-A-based cyanate ester. ORG-biphenol cyanate ester was observed to have a superior glass transition temperature (350–380°C) as compared to bisphenol-A cyanate ester (190–220°C). Cyanate esters derived from bio-oil have the potential to be a sustainable alternative to the bisphenol-A-derived analog.

Sustainable near UV-curable acrylates based on natural phenolics for stereolithography 3D printing

Photocured polymers have recently gained tremendous interest for a wide range of applications especially industrial prototyping/additive manufacturing. This work aims to develop natural phenolic-based (meth)acrylates to expand the use of sustainable and mechanically robust 3D printable formulations.

Multi-component post-polymerization modification reactions of polymers featuring lignin-model compounds

Biomass derived aromatic aldehydes, vanillin and syringaldehyde, were integrated with multicomponent reaction based polymer synthesis.

Bio-based reactive diluents as sustainable replacements for styrene in MAESO resin

Four different biorenewable methacrylated/acrylated monomers, namely, methacrylated fatty acid (MFA), methacrylated eugenol (ME), isobornyl methacrylate (IM), and isobornyl acrylate (IA) were employed as reactive diluents (RDs) to replace styrene (St) in a maleinated acrylated epoxidized soybean oil (MAESO) resin to produce bio-based thermosetting resins using free radical polymerization. The curing kinetics, gelation times, double bond conversions, thermal–mechanical properties, and thermal stabilities of MAESO-RD resin systems were characterized using DSC, rheometer, FT-IR, DMA, and TGA. The results indicate that all four RD monomers possess high bio-based carbon content (BBC) ranging from 63.2 to 76.9% and low volatilities (less than 7 wt% loss after being held isothermally at 30 °C for 5 h). Moreover, the viscosity of the MAESO-RD systems can be tailored to acceptable levels to fit the requirements for liquid molding techniques. Because of the introduction of RDs to the MAESO resin, the reaction mixtures showed an improved reactivity and an accelerated reaction rate. FT-IR results showed that almost all the C Created by potrace 1.16, written by Peter Selinger 2001-2019 ]]> C double bonds within MAESO-RD systems were converted. The glass transition temperatures (T_g) of the MAESO-RDs ranged from 44.8 to 100.8 °C, thus extending the range of application. More importantly, the T_g of MAESO-ME resin (98.1 °C) was comparable to that of MAESO-St resin (100.8 °C). Overall, this work provided four potential RDs candidates to completely replace styrene in the MAESO resin, with the ME monomer being the most promising one.

This paper reports four promising, sustainable reactive diluents to completely replace styrene for a commercially available MAESO resin.

Continuous-flow chemistry for the determination of comonomer reactivity ratios

Continuous-flow chemistry provides an operationally simple and reproducible method for the determination of comonomer reactivity ratios in a single afternoon.

Simple One-Pot Synthesis of Fully Biobased Unsaturated Polyester Resins Based on Itaconic Acid

For the preparation of fully biobased unsaturated polyester resins (UPRs), the replacement of styrene with alternate nonpetroleum-based monomers turned out to be one of the most challenging tasks. Its complexity lies in the fact that reactive diluents (RD) have to have low viscosity and volatility, good compatibility with prepolymer, and capability to homopolymerize and copolymerize with its unsaturations. In this context, we directed our efforts to develop fully biobased UPRs using the dialkyl itaconates as an alternative to styrene. Therefore, a series of 100% biobased UPRs were prepared from itaconic acid and 1,2-propandiol and diluted by dialkyl itaconates. The resins were characterized by Fourier transform infrared spectroscopy, NMR, volatility, and viscosity measurements, while the cured samples were characterized by dynamic mechanical properties, thermomechanical analysis, thermogravimetric analysis data, and tensile tests. The influence of RD structure on the properties of cured samples was discussed in detail. It was shown that the prepared resins had evaporation rates of dialkyl itaconates of several orders of magnitude less compared to styrene. The cured resins with dimethyl itaconate showed comparable or even better thermal and mechanical properties compared to the one with styrene. This investigation showed that itaconic acid and dialkyl itaconates are promising bioresources for the preparation of fully biobased UPRs for mass consumption.

Experimental Data Extraction and in Silico Prediction of the Estrogenic Activity of Renewable Replacements for Bisphenol A

Bisphenol A (BPA) is a ubiquitous compound used in polymer manufacturing for a wide array of applications; however, increasing evidence has shown that BPA causes significant endocrine disruption and this has raised public concerns over safety and exposure limits. The use of renewable materials as polymer feedstocks provides an opportunity to develop replacement compounds for BPA that are sustainable and exhibit unique properties due to their diverse structures. As new bio-based materials are developed and tested, it is important to consider the impacts of both monomers and polymers on human health. Molecular docking simulations using the Estrogenic Activity Database in conjunction with the decision forest were performed as part of a two-tier in silico model to predict the activity of 29 bio-based platform chemicals in the estrogen receptor-α (ERα). Fifteen of the candidates were predicted as ER binders and fifteen as non-binders. Gaining insight into the estrogenic activity of the bio-based BPA replacements aids in the sustainable development of new polymeric materials.

Syringyl Methacrylate, a Hardwood Lignin-Based Monomer for High-Tg Polymeric Materials

As viable precursors to a diverse array of macromolecules, biomass-derived compounds must impart wide-ranging and precisely controllable properties to polymers. Herein, we report the synthesis and subsequent reversible addition-fragmentation chain-transfer polymerization of a new monomer, syringyl methacrylate (SM, 2,6-dimethoxyphenyl methacrylate), that can facilitate widespread property manipulations in macromolecules. Homopolymers and heteropolymers synthesized from SM and related monomers have broadly tunable and highly controllable glass transition temperatures ranging from 114 to 205 °C and zero-shear viscosities ranging from ∼0.2 kPa·s to ∼17,000 kPa·s at 220 °C, with consistent thermal stabilities. The tailorability of these properties is facilitated by the controlled polymerization kinetics of SM and the fact that one vs two o-methoxy groups negligibly affect monomer reactivity. Moreover, syringol, the precursor to SM, is an abundant component of depolymerized hardwood (e.g., oak) and graminaceous (e.g., switchgrass) lignins, making SM a potentially sustainable and low-cost candidate for tailoring macromolecular properties.