Melt processable cellulose fibres engineered for replacing oil-based thermoplastics

If cellulosic materials are to replace materials derived from non-renewable resources, it is necessary to overcome intrinsic limitations such as fragility, permeability to gases, susceptibility to water vapour and poor three-dimensional shaping. Novel properties or the enhancement of existing properties are required to expand the applications of cellulosic materials and will create new market opportunities. Here we have overcome the well-known restrictions that impede melt-processing of high cellulose content composites. Cellulose fibres, partially derivatised to dialcohol cellulose, have been used to manufacture three-dimensional high-density materials by conventional melt processing techniques, with or without the addition of a thermoplastic polymer. This work demonstrates the use of melt processable chemically modified cellulose fibres in the preparation of a new generation of highly sustainable materials with tuneable properties that can be tailored for specific applications requiring complex three-dimensional parts.