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Optimizing Wood-Hemp-Sodium Silicate Composites for Strength, Extrudability, and Cost in Additive Manufacturing

Nagendra G Tanikella1, Armando G McDonald2, Michael R Maughan1

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Summary

Sustainable additive manufacturing (AM) is advanced by using wood and hemp byproducts. A wood-sodium silicate composite with pellet wood fibers and hemp hurd demonstrated excellent strength-to-cost ratio and processability.

Keywords:
additive manufacturingfiberhemphurdthermosetsvalue engineeringwood

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Area of Science:

  • Materials Science
  • Sustainable Manufacturing

Background:

  • Additive manufacturing (AM) seeks sustainable materials to reduce costs and environmental impact.
  • Forestry and agricultural byproducts offer potential as eco-friendly feedstock for AM.

Purpose of the Study:

  • To develop and characterize wood-sodium silicate composites with hemp hurd and fibers for AM.
  • To optimize composite formulations for mechanical properties, processability, and cost-effectiveness.

Main Methods:

  • Formulations varied wood fiber type, sodium silicate concentration, and hemp hurd content.
  • Evaluated material properties including rheology, extrusion, bulk density, flexural, and compressive strengths.
  • Conducted cost analysis and assessed strength-to-cost ratios.

Main Results:

  • Rheology and extrusion performance were significantly influenced by sodium silicate content.
  • Increased liquid content initially raised viscosity, then decreased it at higher concentrations.
  • Finer particle sizes generally improved mechanical strengths.
  • A formulation with pellet wood fibers, 55 wt% sodium silicate, and 10 wt% hemp hurd achieved a high strength-to-cost ratio (73.0 MPa/$) with low motor power.

Conclusions:

  • Wood and hemp byproducts can be effectively utilized in sodium silicate composites for sustainable AM.
  • Optimized formulations balance mechanical performance, processability, and economic viability.
  • The identified optimal formulation presents a promising sustainable material for additive manufacturing applications.