Prospects for manufacturing of complex 3D-shaped all-cellulose composites

All-cellulose composites (ACC) have been investigated as a high-strength bio-based alternative to commodity plastics. However, plastic products frequently demand complex 3D geometries as part of their functionality. Hence, a critical factor in the broader application of ACCs is the production of dimensionally-accurate 3D forms. Interestingly, there have been no attempts in the literature to produce 3D geometries based on all-cellulose composites. In the present work, the production of ACCs with 3D geometries is explored for the first time using conventional vacuum and compression moulding procedures. The level of 3D complexity possible in ACCs was examined using a closed mould design that incorporated a range of geometric shapes and angles of varying intricacy. The dimensional accuracy of the final 3D forms was analysed via 3D laser scanning of the surfaces of the as-moulded ACCs. The choice of coagulant type was found to strongly influence the dimensional accuracy of the as-moulded ACCs.