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DOE OSTI · 3367075

Utilization of Hemp Processing Waste for 3D Printing of Biocomposites

Ji, Anqi [Howard University, Washington, DC (United States)] (ORCID:0009000641299266)·Han, Nara [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States); Inha University, Incheon (Korea, Republic of)]·Zhang, Shuyang [University of Tennessee, Knoxville, TN (United States)]·Pearson, Soya [Howard University, Washington, DC (United States)]·Zhao, Xianhui [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000202825810)·Thapa, Santosh [South Dakota State University, Brookings, SD (United States)]·Karki, Bishnu [South Dakota State University, Brookings, SD (United States)]·Lee, Seoku [Hanyang University, Seoul (Korea, Republic of)]·Ragauskas, Arthur J. [University of Tennessee, Knoxville, TN (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); University of Tennessee Institute of Agriculture, Knoxville, TN (United States)] (ORCID:000000023536554X)·Vyas, Diwakar [University of Florida, Gainesville, FL (United States)]·Kumar, Deepak [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States)]·Wie, Jeong Jae [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States); Hanyang University, Seoul (Korea, Republic of)]·Yoo, Chang Geun [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States)] (ORCID:0000000261792414)
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Abstract

Unlike stem biomass, the residues after the extraction of cannabidiol (CBD) oil from hemp flower are challenging to utilize because of their high extractive content (~ 40%, mainly lipids) and are typically considered waste and landfilled. This study presented a novel approach to effectively valorize this underutilized hemp processing waste via chemical processing for three-dimensional (3D) printing applications. Hemp processing waste was processed with sodium hydroxide (NaOH) to control extractives for solving nozzle clogging and then applied as a biofiller in polylactic acid (PLA) composites to improve the mechanical strength. The novelty of this work lies in demonstrating that controlled extractive removal via NaOH treatment not only improves processability but also enhances mechanical performance in 3D-printed biocomposites. We systematically investigated the effect of the processed biofiller content (2.5–10 wt%) on the mechanical and thermal properties of the biocomposites. The decrease in the content of extractives reduced the non-structural components and improved the surface compatibility of the hemp waste with the PLA matrix, thereby enhancing the polymer-biofiller interactions. The best performance was achieved at 2.5 wt% loading, where Young’s modulus increased from 2.3 GPa to 2.6 GPa and tensile strength from 42.7 MPa to 48.8 MPa. Interestingly, the complete removal of extractives also reduced the mechanical strength of their biocomposites, indicating the interfacial adhesion effects of extractives. Furthermore, this study provides new insights into balancing extractive content for optimal mechanical properties, offering a sustainable solution for waste valorization in additive manufacturing.

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Additive manufacturingBiocompositeBiomass wasteSustainable materialsWaste valorization

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Ji, Anqi [Howard University, Washington, DC (United States)] (ORCID:0009000641299266), Han, Nara [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States); Inha University, Incheon (Korea, Republic of)], Zhang, Shuyang [University of Tennessee, Knoxville, TN (United States)], Pearson, Soya [Howard University, Washington, DC (United States)], Zhao, Xianhui [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000202825810), Thapa, Santosh [South Dakota State University, Brookings, SD (United States)], Karki, Bishnu [South Dakota State University, Brookings, SD (United States)], Lee, Seoku [Hanyang University, Seoul (Korea, Republic of)], Ragauskas, Arthur J. [University of Tennessee, Knoxville, TN (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); University of Tennessee Institute of Agriculture, Knoxville, TN (United States)] (ORCID:000000023536554X), Vyas, Diwakar [University of Florida, Gainesville, FL (United States)], Kumar, Deepak [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States)], Wie, Jeong Jae [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States); Hanyang University, Seoul (Korea, Republic of)], Yoo, Chang Geun [State University of New York College of Environmental Science and Forestry, Syracuse, NY (United States)] (ORCID:0000000261792414). 2025-09-16. Utilization of Hemp Processing Waste for 3D Printing of Biocomposites. https://doi.org/10.1007/s12649-025-03314-z

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