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Sustainability
Volume 17
Issue 23
10.3390/su172310461
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Kinetics and Mechanical Performance of Bio-Based Polyurethane Wood Composites for Sustainable 3D-Printed Construction Materials

by
Lucila M. Carias Duron
1,2,
Jesus Granero Garcia
1,
Chetna Mandurai
3,
Jordon Hoyer
1,
Japneet Kukal
4,
Manish Sakhakarmy
5,
Sushil Adhikari
5,
Brian Via
6,
Iris Beatriz Vega Erramuspe
5,6,
Armando G. McDonald
4 and
Maria L. Auad
1,2,*
1
Center for Polymers and Advanced Composites, Gavin Engineering Research Laboratory, Auburn University, 311 West Magnolia Avenue, Auburn, AL 36849, USA
2
Department of Chemical Engineering, Ross Hall, Auburn University, 222 Foy Union Circle, Auburn, AL 36849, USA
3
Department of Chemical Engineering, The University of Tulsa, Keplinger Hall, 800 S. Tucker Drive, Tulsa, OK 74104, USA
4
Department of Forest, Rangeland and Fire Sciences, University of Idaho, 875 Perimeter Drive MS 1133, Moscow, ID 83844, USA
5
Department of Biosystems Engineering, Auburn University, 209 Tom E. Corley Building, Auburn, AL 36849, USA
6
Forest Products Development Center, School of Forestry and Wildlife Science, Auburn University, 520 Devall Drive, Auburn, AL 36849, USA
*
Author to whom correspondence should be addressed.
Sustainability 2025, 17(23), 10461; https://doi.org/10.3390/su172310461
Submission received: 30 October 2025 / Revised: 17 November 2025 / Accepted: 18 November 2025 / Published: 21 November 2025
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Abstract

Developing bio-based polyurethane (BPU) composites that incorporate bio-oil and wood dust as sources of hydroxyl groups (-OH) presents a compelling approach to advancing sustainable polymer systems. This study examines the impact of isocyanate-to-hydroxyl equivalent ratios and varying proportions of bio-oil and wood dust on the processability and mechanical properties of molded composite panels. Formulations were systematically optimized based on equivalent ratio calculations to enhance extrusion behavior and final structural performance. Extrusion trials demonstrated that an -NCO/-OH ratio of 1.5:1, with 50% wood dust serving as an -OH donor, resulted in the most stable material flow, characterized by minimized surface defects and an ideal viscosity for processing. Compression molding and mechanical testing revealed that a balanced formulation with 50% bio-oil and 50% wood dust, with an equivalent ratio of -OH groups, achieved the best combination of Young’s modulus, stress, and strain performance, even under wet conditions. SEM confirmed improved filler dispersion and interfacial adhesion in these optimized systems. Although full 3D-printing trials were not conducted, the observed extrusion stability and controlled curing behavior indicate strong potential for application in extrusion-based additive manufacturing. These results highlight that precise resin–filler balancing enables continuous extrusion, structural resilience, and reduced activation energy, reinforcing the viability of BPUs as scalable, sustainable materials for construction and additive manufacturing.
Keywords: bio-based polyurethane; wood dust reinforcement; hydroxyl functionality; bio-based resin systems; bio-oil; extrusion processability; sustainable composites bio-based polyurethane; wood dust reinforcement; hydroxyl functionality; bio-based resin systems; bio-oil; extrusion processability; sustainable composites
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MDPI and ACS Style

Carias Duron, L.M.; Granero Garcia, J.; Mandurai, C.; Hoyer, J.; Kukal, J.; Sakhakarmy, M.; Adhikari, S.; Via, B.; Vega Erramuspe, I.B.; McDonald, A.G.; et al. Kinetics and Mechanical Performance of Bio-Based Polyurethane Wood Composites for Sustainable 3D-Printed Construction Materials. Sustainability 2025, 17, 10461. https://doi.org/10.3390/su172310461

AMA Style

Carias Duron LM, Granero Garcia J, Mandurai C, Hoyer J, Kukal J, Sakhakarmy M, Adhikari S, Via B, Vega Erramuspe IB, McDonald AG, et al. Kinetics and Mechanical Performance of Bio-Based Polyurethane Wood Composites for Sustainable 3D-Printed Construction Materials. Sustainability. 2025; 17(23):10461. https://doi.org/10.3390/su172310461

Chicago/Turabian Style

Carias Duron, Lucila M., Jesus Granero Garcia, Chetna Mandurai, Jordon Hoyer, Japneet Kukal, Manish Sakhakarmy, Sushil Adhikari, Brian Via, Iris Beatriz Vega Erramuspe, Armando G. McDonald, and et al. 2025. "Kinetics and Mechanical Performance of Bio-Based Polyurethane Wood Composites for Sustainable 3D-Printed Construction Materials" Sustainability 17, no. 23: 10461. https://doi.org/10.3390/su172310461

APA Style

Carias Duron, L. M., Granero Garcia, J., Mandurai, C., Hoyer, J., Kukal, J., Sakhakarmy, M., Adhikari, S., Via, B., Vega Erramuspe, I. B., McDonald, A. G., & Auad, M. L. (2025). Kinetics and Mechanical Performance of Bio-Based Polyurethane Wood Composites for Sustainable 3D-Printed Construction Materials. Sustainability, 17(23), 10461. https://doi.org/10.3390/su172310461

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