Expanded polystyrene (EPS) remains a popular packaging material despite environmental concerns such as pollution, difficulty to recycle, and toxicity to wildlife. The goal of this study is to evaluate the potential of an ecofriendly alternative to traditional EPS composed of a mycelium biocomposite grown from agricultural waste. In this material, the mycelium spores are incorporated into cellulosic waste, resulting in a structurally sound biocomposite completely enveloped by mycelium fibers. One of the main criteria for shipping applications is the ability of a material to withstand extreme weather conditions. Accordingly, this study focused on evaluating a commercially available mycelium material before and after exposure to various weathering conditions, including high and low temperatures at different humidity levels. Fourier transform infrared spectroscopy (FTIR) was performed to examine any transformations in the mycelium structure and composition, whereas scanning electron microscopy (SEM) was used to reveal any changes in the morphology. Similarly, thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) analyses were conducted to evaluate the thermal behavior, whereas mechanical properties were measured by using shore hardness and Izod Impact testing. Although some irreversible changes were observed due to the exposure to high temperatures, the material exhibited good thermal stability and impact resistance. FTIR analysis demonstrated small changes in the biocomposite structure and protein rearrangement as a result of weathering, whereas SEM revealed some cracking in the cellulose substrate. A combination of low temperatures and humidity resulted in significant moisture absorption, as indicated by TGA and DSC. This in turn decreased the hardness of the fibers by nearly 2-fold; however, the impact strength of the entire biocomposite remained unchanged. Overall, these results provide important insight into the structure-property relationships of mycelium-based materials.

This paper evaluates the design and fabrication of a thermoplastic polyurethane (TPU) shape memory polymer (SMP) using fused deposition modeling (FDM). The commercially available SMP filament was used to create parts capable of changing their shape following the application of an external heat stimulus. The characterization of thermal and viscoelastic properties of the SMP TPU revealed a proportional change in shape fixity and recovery with respect to heating and cooling rates, as well as a decreasing softening temperature with increasing shape memory history due to changes in the polymer microstructure. Inspired by the advancements in 3D and 4D printing, we investigated the feasibility of creating multi-material lattice structures using SMP and another thermoplastic with poor adhesion to TPU. A variety of interlocking lattice structures were evaluated by combining SMP with another thermoplastic that have poor adhesion with TPU. The tensile strength and failure modes of the fabricated multi-material parts were compared against homogenous SMP TPU specimens. It was found that the lattice interface failed first at approximately 41% of the ultimate strength of the homogenous part on average. The maximum recorded ultimate strength of the multi-material specimens reached 62% of SMP TPU’s ultimate strength. These characterizations can make 4D printing technology more accessible to common users and make it available for new markets.

This study investigates the development of biodegradable chitosan-based films as a sustainable alternative to conventional non-biodegradable food packaging materials. Chitosan, a naturally occurring polymer, possesses inherent film-forming ability and biodegradability; however, its limited mechanical and thermal properties constrain its practical applications. In this work, chitosan films were fabricated via compression molding, and their thermo-mechanical performance was systematically evaluated. The incorporation of fillers, such as titanium dioxide and silica, resulted in a 50% enhancement in tensile strength and an 86% improvement in flexibility. Further optimization of dual-filler compositions led to an additional 45% increase in elasticity, demonstrating the potential of synergistic reinforcement. These findings underscore the viability of tailored chitosan composites as high-performance, biodegradable materials for the next generation of sustainable materials.

This study investigated the properties of red algae (RA) biocomposite films reinforced with natural sisal fibers and plasticized with glycerol. The polymer was extracted from locally sourced red seaweed and combined sisal fibers at varying fiber loadings (0–45 wt%) using the doctor blading technique. Composite films were analyzed using a variety of methods to evaluate the chemical composition, thermal behavior and mechanical performance. Infrared spectroscopy confirmed the presence of kappa-carrageenan as the dominant polysaccharide in the RA matrix, whereas elemental analysis verified the dilution of sulfur content and enrichment of carbon with increasing fiber incorporation. Thermal stability increased with fiber loading, peaking at 30 wt% sisal fiber before decreasing slightly at 45 wt% due to poor fiber dispersion. Mechanical testing demonstrated an optimal balance between strength and flexibility at 30 wt% sisal fiber, with a 37% increase in strength compared to the pure RA film. Overall, the findings demonstrate that sisal fiber reinforcement enhances the structural integrity and stability of RA-based films, supporting their potential as biodegradable alternatives to petroleum-based plastics.