Functional lignin-based 4D composites by additive manufacturing with A.I. improved magnetic triggering performance – MAGNELIN4D

Lignin was functionalized using reagents derived from vegetable oil via homogeneous catalysis. Grafting of pre-allylated glycerol carbonate led to functionalization rates above 80%. Methyl 10-undecenoate, a bio-sourced reagent, was then grafted onto lignin via a second metathesis step, with optimal parameters obtained at 80°C for 6 hours (100% conversion). A second transformation route was also established by reaction simplification. Methyl 10-undecenoate was epoxidized and then grafted onto lignin with a very high substitution rate of the hydroxyl groups of lignin, including all phenols. Thermal analyses (DSC and TGA) carried out on the modified lignin and PA/lignin blends revealed the improved compatibility between PA and lignin. A comparative analysis was carried out for filaments containing lignin with PLA, ABS, PA and magnetic filaments: PE, ABS, PEEK, TPU/ferrites, neodymium, magnetite, MnAlC. The study of the commercial ferromagnetic composite PLA/printed iron oxide with a saturation magnetization of 0.15 T and a magnetic permeability of 10-5 H/m, made it possible to determine the tensile performance with a mechanical strength of 45 MPa. The analysis by SEM and RX tomography highlighted an oxide connectivity rate of 22% for 19% of loading rates, and a generated porosity of up to 40%.

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Simon, C.; Dumont, C.; Sauthier, M. Functionalization of lignin for the manufacture of 4D printing filaments, Congrès JNOEJC 2023. Lille, 1-2 juin 2023.

Bouchetara, M.; Belhabib, S.; Weitkamp, T.; Tahlaiti, M.; Nouri, M.; Guessasma, S. Effect of printing temperature on the microstructure and mechanical performance of 3D printed magnetic PLA, to be submitted to Polymers. (under submission).

MAGNELIN4D is a multidisciplinary project that aims at developing new smart materials with programmable magnetic actuation using additive manufacturing and artificial intelligence. MAGNELIN4D gathers a consortium of 4 academic partners and 1 SEM to perform an applied research balanced between material formulation and functionalisation, polymer processing, numerical modelling and process control using artificial intelligence. MAGNELIN4D has four defined targets: 1- Develop a biosourced magnetic filament with high-lignin load 2- Prove this new filament relevance in industrial environment, 3- Build an artificial intelligence control environment for 4D printing, and 4- Achieve new 3D designs with magnetic actuation capabilities. MAGNELIN4D novel solutions will feed key industrial sectors such as electronics, utilities, materials, energy and healthcare. MAGNELIN4D intends to have a large impact in AM industry and usages, by involving end-users at the first steps of the project and by addressing production upscaling of bio-based magnetic filaments for future industrialisation.