We report a transformative epoxy system with a microalgae-derived bio-binder from hydrothermal liquefaction processing (HTL). The obtained bio-binder not only served as a curing agent for conventional epoxy resin (e.g., EPON 862), but also acted as a modifying agent to enhance the thermal and mechanical properties of the conventional epoxy resin. This game-changing epoxy/bio-binder system outperformed the conventional epoxy/hardener system in thermal stability and mechanical properties. Compared to the commercial EPON 862/EPIKURE W epoxy product, our epoxy/bio-binder system (35 wt.% bio-binder addition with respect to the epoxy) increased the temperature of 60% weight loss from 394 °C to 428 °C and the temperature of maximum decomposition rate from 382 °C to 413 °C, while the tensile, flexural, and impact performance of the cured epoxy improved in all cases by up to 64%. Our research could significantly impact the USD 38.2 billion global market of the epoxy-related industry by not only providing better thermal and mechanical performance of epoxy-based composite materials, but also simultaneously reducing the carbon footprint from the epoxy industry and relieving waste epoxy pollution.

In the present study experimental and numerical investigations were carried out to predict the low velocity impact response of four symmetric configurations: 10 ply E Glass, 10 ply AS4 Carbon, and two Hybrid combinations with 1 and 2 outer plies of E Glass and 8 and 6 inner plies of Carbon. All numerical investigations were performed using commercial finite element software, LS-DYNA. The test coupons were manufactured using the low cost Heated Vacuum Assisted Resin Transfer Molding (H-VARTM©) technique. Low velocity impact testing was carried out using an Instron Dynatup 8250 impact testing machine. Standard 6 × 6 Boeing fixture was used for all impact experiments. Impact experiments were performed over progressive damage, that is, from incipient damage till complete failure of the laminate in six successive impact energy levels for each configuration. The simulation results for the impact loading were compared with the experimental results. For both nonhybrid configurations, it was observed that the simulated results were in good agreement with the experimental results, whereas, for hybrid configurations, the simulated impact response was softer than the experimental response. Maximum impact load carrying capacity was also compared for all four configurations based on their areal density. It was observed that Hybrid262 configuration has superior impact load to areal density ratio.