3D printing of sustainable wood-based bio-composites for high-end custom carton

This research delves into an upscale, personalised packaging paradigm employing 3D printing and a bio-composite derived from esteemed rosewood. The study incorporates a design for additive manufacturing, enhancing designers’ flexibility, and fostering innovation. To address global sustainability imperatives, including efficiency, energy conservation, a low carbon footprint and ecological compatibility, a premium and sustainable rosewood/polyethersulfone (PES) composite is developed. Laser sintering (LS), renowned for its processing flexibility, is applied for crafting intricate packages. A weight ratio of 1:4 of rosewood to PES is highly suitable for LS processing. The resultant custom carton, embodying natural rosewood aesthetics and fragrance, exhibits commendable mechanical robustness and precision. Tensile and bending strengths reach peaks of 4.880 MPa and 7.870 MPa, respectively, under a 9-W laser power. Scanning electron microscope (SEM) analysis confirms the favourable dispersion of rosewood fibres in LS specimens, providing insights into the microstructure of the composite powder.