Accurate additive manufacturing of lightweight and elastic carbons using plastic precursors.

Despite groundbreaking advances in the additive manufacturing of polymers, metals, and ceramics, scaled and accurate production of structured carbons remains largely underdeveloped. This work reports a simple method to produce complex carbon materials with very low dimensional shrinkage from printed to carbonized state (less than 4%), using commercially available polypropylene precursors and a fused filament fabrication-based process. The control of macrostructural retention is enabled by the inclusion of fiber fillers regardless of the crosslinking degree of the polypropylene matrix, providing a significant advantage to directly control the density, porosity, and mechanical properties of 3D printed carbons. Using the same printed plastic precursors, different mechanical responses of derived carbons can be obtained, notably from stiff to highly compressible. This report harnesses the power of additive manufacturing for producing carbons with accurately controlled structure and properties, while enabling great opportunities for various applications.

Direct synthesis of ordered mesoporous materials from thermoplastic elastomers.

The ability to manufacture ordered mesoporous materials using low-cost precursors and scalable processes is essential for unlocking their enormous potential to enable advancement in nanotechnology. While templating-based methods play a central role in the development of mesoporous materials, several limitations exist in conventional system design, including cost, volatile solvent consumption, and attainable pore sizes from commercial templating agents. This work pioneers a new manufacturing platform for producing ordered mesoporous materials through direct pyrolysis of crosslinked thermoplastic elastomer-based block copolymers. Specifically, olefinic majority phases are selectively crosslinked through sulfonation reactions and subsequently converted to carbon, while the minority block can be decomposed to form ordered mesopores. We demonstrate that this process can be extended to different polymer precursors for synthesizing mesoporous polymer, carbon, and silica. Furthermore, the obtained carbons possess large mesopores, sulfur-doped carbon framework, with tailorable pore textures upon varying the precursor identities.

Multifunctional Carbon Fibers from Chemical Upcycling of Mask Waste.

Over the past years, disposable masks have been produced in unprecedented amounts due to the COVID-19 pandemic. Their increased use imposes significant strain on current waste management practices including landfilling and incineration. This results in large volumes of discarded masks entering the environment as pollutants, and alternative methods of waste management are required to mitigate the negative effects of mask pollution. While current recycling methods can supplement conventional waste management, the necessary processes result in a product with downgraded material properties and a loss of value. This work introduces a simple method to upcycle mask waste into multifunctional carbon fibers through simple steps of thermal stabilization and pyrolysis. The pre-existed fibrous structure of polypropylene masks can be directly converted into carbonaceous structures with high degrees of carbon yield, that are inherently sulfur-doped, and porous in nature. The mask-derived carbon product demonstrates potential use in multiple applications such as for Joule heating, oil adsorption, and the removal of organic pollutants from aqueous environments. We believe that this process can provide a useful alternative to conventional waste management by converting mask waste generated during the COVID-19 pandemic into a product with enhanced value.