Additive Manufacturing of Carbon Using Commodity Polypropylene
Abstract
Carbon materials are essential to the development of modern society with indispensable use in various applications, such as energy storage and high‐performance composites. Despite great progress, on‐demand carbon manufacturing with control over 3D macroscopic configuration is still an intractable challenge, hindering their direct use in many areas requiring structured materials and products. This work introduces a simple and scalable method to generate complex, large‐scale carbon structures using easily accessible materials and technologies. 3D‐printed, commercial polypropylene (PP) parts can be thermally stabilized through cracking‐facilitated diffusion and crosslinking. The newly elucidated mechanism from this work allows thick PP parts to yield carbonaceous products with complex structures through a subsequent pyrolysis step. The approach for enabling PP‐to‐carbon conversion has consistent product yield and controlled dimensional shrinkage. Under optimized processing conditions, these PP‐derived carbons exhibit robust mechanical properties and excellent joule heating performance, demonstrated by their versatile use as heating elements. Furthermore, this process can be extended to recycled PP, enabling the conversion of waste plastic materials to value‐added products. This work provides an innovative approach to create structured carbon materials with direct access to complex geometry, which can be transformative to, and broadly benefit, many important technological applications.
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Smith and colleagues developed a simple and scalable method to produce complex structured carbon from commodity polypropylene.
“Smith and colleagues developed a simple and scalable method to produce complex structured carbon from commodity PP (Fig. 8c) [104] .”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [104]
After carbonization, a high carbon recovery rate of up to 62 wt% was achieved.
“After carbonization, a high carbon recovery rate of up to 62 wt% was achieved.”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [104]
The honeycomb-like carbon structure, despite containing crack defects, exhibits exceptional mechanical strength, with load-bearing capacity per unit density exceeding that of the precursor by over 5,300-fold.
“Performance characterization demonstrated that this honeycomb-like carbon structure, despite containing crack defects, exhibits exceptional mechanical strength, with a load-bearing capacity per unit density exceeding that of the precursor by over 5,300-fold.”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [104]
The honeycomb-like carbon structure also possesses rapid Joule response characteristics.
“It also possesses rapid joule response characteristics.”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [104]
The 3D printing-derived method can be applied to the production of various carbon materials with complex structures.
“This method can be applied to the production of various carbon materials with complex structures.”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [104]
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Self-citationEnabling 3D printing of carbons by polyethylene precursors
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Tuning Polyolefin Hydrophilicity to Control Sulfonation Cross-Linking Kinetics for Carbon Synthesis
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Precisely 3D printing of ultrastrong architected carbon with a bio-inspired superstructurePreprint
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Self-citation
- Authors
- Smith, P., Obando, A. G., Griffin, A., Robertson, M., Bounds, E., & Qiang, Z.
- Affiliations
- University of Southern Mississippi (US)
- School of Polymer Science and Engineering The University of Southern Mississippi 118 College Drive Hattiesburg MS 39406 USA
- Corresponding author
- Qiang, Zhe
- Venue
- Advanced Materials
- Publisher
- Wiley
- Published
- 2023-03-17
- Volume
- 35
- Issue
- 17
- Pages
- e2208029-e2208029
- ISSN
- 0935-9648 (ISSN-L)
- 1521-4095
- OpenAlex
- W4319812815
- Cited by
- 42
- References
- 84
- Citations by year
- 2026: 7 · 2025: 16 · 2024: 12 · 2023: 7
- FWCI
- 3.04
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Advanced Materials (publishedVersion)
- PubMed (publishedVersion)
- Aquila Digital Community (University of Southern Mississippi) (submittedVersion)
- Funders
- University of Southern Mississippi
- Topics
- Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
- Physical Sciences › Materials Science › Materials Chemistry › Graphite, nuclear technology, radiation studies
- Physical Sciences › Materials Science › Materials Chemistry › Carbon Nanotubes in Composites
- Keywords
- pyrolysis, crosslinking, Joule heating, waste plastic recycling, dimensional shrinkage, heating elements
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