Safer materials in 3D printing: research into fire-resistant nanocomposites

A research team at Oklahoma State University is investigating the thermal properties of biopolymer nanocomposites in 3D printing. Led by Dr. Ryan Shen, assistant professor of Fire Protection and Safety Engineering Technology, the fire and materials research aims to help make 3D printed objects safer and more sustainable.

“We’re working on developing special plastic materials (called nanocomposites) for 3D printing that are less likely to catch fire and burn intensively,” Shen said. “To do this, we’ll mix very tiny particles with the plastic used in 3D printing to make it safer and more durable.”

The study focuses on the interactions between heat and material structure during the ignition and combustion of 3D-printed components. Due to the layer-by-layer production, microscopic cavities and structures are created in these components that can influence the fire behavior. The researchers use the Cone Calorimeter to analyze the thermal load capacity and store temperature data with the National Instruments CompactDAQ system to enable detailed measurements of heat transfer.

“My work has always been driven by the belief that engineering solutions can have a direct and meaningful impact on public safety and environmental sustainability,” Shen said. “Safer 3D-printed materials can prevent fires, save lives, and reduce environmental and economic losses.”

The aim of the research is to develop new nanocomposites that are less susceptible to ignition. To this end, fire-retardant nanoparticles are integrated into biopolymers to minimize the risk of uncontrolled combustion. In the automotive sector in particular, this could bring significant safety benefits by developing fire-resistant materials for use in lightweight, additively manufactured vehicle components. These measures should both increase passenger safety and reduce potential damage in the event of a fire.

“By integrating this research into the classroom, students will gain practical knowledge, critical thinking skills and exposure to state-of-the-art fire safety technologies, ensuring they graduate well-equipped to address modern fire safety challenges in both academic and professional settings,” Shen said.

The findings from this project will be incorporated into courses to provide students with practical knowledge of modern fire safety technologies. The research could not only increase the safety of 3D-printed products, but also further strengthen the university’s position as a leading institution for fire protection technology.