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This paper describes the use of fused deposition modeling (FDM) printing to fabricate paper-based analytical devices (PAD) with three-dimensional (3D) features, which is termed as 3D-PAD. Material depositions followed by heat reflow is a standard approach for the fabrication of PAD. Such devices are primarily two-dimensional (2D) and can hold only a limited amount of liquid samples in the device. This constraint can pose problems when the sample consists of organic solvents that have low interfacial energies with the hydrophobic barriers. To overcome this limitation, we developed a method to fabricate PAD integrated with 3D features (vertical walls as an example) by FDM 3D printing. 3D-PADs were fabricated using two types of thermoplastics. One thermoplastic had a low melting point that formed hydrophobic barriers upon penetration, and another thermoplastic had a high melting point that maintained 3D features on the filter paper without reflowing. We used polycaprolactone (PCL) for the former, and polylactic acid (PLA) for the latter. Both PCL and PLA were printed with FDM without gaps at the interface, and the resulting paper-based devices possessed hydrophobic barriers consisting of PCL seamlessly integrated with vertical features consisting of PLA. We validated the capability of 3D-PAD to hold 30 μL of solvents (ethanol, isopropyl alcohol, and acetone), all of which would not be retained on conventional PADs fabricated with solid wax printers. To highlight the importance of containing an increased amount of liquid samples, a colorimetric assay for the formation of dimethylglyoxime (DMG)-Ni (II) was demonstrated using two volumes (10 μL and 30 μL) of solvent-based dimethylglyoxime (DMG). FDM printing of 3D-PAD enabled the facile construction of 3D structures integrated with PAD, which would find applications in paper-based chemical and biological assays requiring organic solvents.

The development of all-bio-based composites is one of the relevant aspects of pursuing a carbon-neutral economy. This study aims to explore the possibility to reinforce polylactic acid by the combination of cellulose and chitin nanofibers instead of a single reinforcement phase. Polylactic acid colloidal suspension, cellulose and chitin nanofiber suspensions were mixed using only water as mixing medium and subsequently dewatered to form paper-like sheets. Sheets were hot pressed to melt the polylactic acid and form nanocomposites. The combination of cellulose and chitin nanofiber composites delivered higher tensile properties than its counterparts reinforced with cellulose or chitin nanofibers alone. Cellulose and chitin appear to complement each other from the aspect of the formation of a rigid cellulose nanofiber percolated network, and chitin acting as a compatibilizer between hydrophobic polylactic acid and hydrophilic cellulose.

Background, aim, and scope: Packaging uses nearly 40% of all polymers, a substantial share of which is used for sensitive merchandise such as moisture-sensitive food. To find out if bio-based materials are environmentally advantageous for this demanding application, we compared laminated, printed film across the whole life cycle. Materials and methods: We compared bio-based materials (paper, polylactic acid, bio-based polyethylene, and a biobased polyester) as well as conventional ones (polypropylene, polyethylene). Data stemmed from13 companies that produce raw materials, films and/or laminates and which co-operated with us in a project commissioned by a large food producer. The functional unit chosen for this study is 1 m2 of packaging film. This is (mostly) laminated, printed film that is delivered on reels to the food industry, where the laminate is cut, sealed and filled. The impact assessment is presented for non-renewable energy use, total energy use, global warming potential, depletion of abiotic resources, photo-oxidant formation, acidification, eutrophication, water use, and land use. Results: For Inner Packs that get in direct contact with food and therefore require certain barrier properties, the environmental performance of many laminates is not better than the reference, petrochemical material. However, our study shows that paper/polypropylene laminates perform equally well as the current material (polypropylene) if the material is landfilled, and better if incinerated with energy recovery. For Outer Packs, bio-based polyethylene film shows a particularly low environmental impact. Paper/bio-based polyester laminates also offer significant savings compared with the current material. For Inner as well as Outer Packs, laminates including polylactic acid offer environmental advantages when accounting for wind credits or when assuming a future technology level for polymer or film production. Discussion: Increased technology maturity of PLA and cellulose in the film production stage offers significant environmental improvement with respect to global warming potential compared with today's technology. Though large, the uncertainty regarding the degree of degradation of paper, cellulose, PLA and bio-based polyester, is not decisive for the conclusions. Conclusions and recommendations: Generally, laminates and films (partly) consisting of bio-based polymers offer opportunities for significantly reducing environmental impacts of food packaging. Large variations in land-use are possible depending on the type of bio-based material that is used. The environmental advantages differ depending on the polymer and the final product (Inner vs. Outer Pack). Lack of experience and investment in converting bio-based polymers into final products and comparatively unfavourable material properties result in lower environmental advantages for some novel bio-based materials than one may expect. However, a) already today, the options with the lowest global warming potential are partly or fully bio-based and b) bio-based materials will benefit more from technological progress than conventional materials, potentially making certain bio-based laminates highly attractive options for the future. Overall, Outer Packs are more promising than Inner Packs when introducing bio-based wrappings to replace the current petrochemical material because a) the opportunities are clearer for this application and b) the product specifications (required barrier properties) are less demanding. Starting with the Outer Packs would also allow bio-based polymer producers and processors to invest and learn, thus offering the opportunity to reduce the environmental impact even further.