Combination and processing keratin with lignin as biocomposite materials for additive manufacturing technology

Additive manufacturing using Nature's resources is a desirable goal. In this work we examine how the inherent macromolecular properties of keratin and lignin can be utilised and developed using green chemistry principles to form 4D functional materials. A new methodology utilising protein complexation by lignin was applied to form copolymers and reinforce keratin cross-linking networks on aqueous and solid state processing. Solubility, chemical and processing characteristics found a favoured 4:1 ratio of keratin to lignin was most desired for effective further processing as 3D printed paste forms. Thermally processing keratin-lignin with plasticisers and processing aids demonstrated extruded FDM filaments could be formed at temperatures >130°C, but degradation of keratin-lignin materials was observed. Employing paste printing strategies, keratin-lignin hydrogels could successfully print 3D skirt outlines. This was achieved with aqueous hydrogels prepared at 30–40% solids content with and without plasticizers over a defined processing timeframe. Mechanical response to moisture stimuli was successfully demonstrated for the 4:1 keratin-lignin printed material on water soaking, realising the ability of these keratin-lignin biocomposite materials to introduce a 4th dimensional response after 3D printing.