Integration of Algae-Based Biochar Core-Shell Particles in Thermoplastic Composites: Correlating Feedstock, Processing Techniques, and Interfacial Design with Mechanical Performance

• Rebecca Stutzman, Chemical Engineering, University of Delaware

• Srikanth Pilla, Center for Composites Materials, University of Delaware

As the automotive industry strives to improve fuel efficiency, replacing metallic structures with polymer composites can reduce vehicle weight by up to 50%, thus boosting fuel economy by 6%-8%. Novel bio-derived engineered fillers are gaining traction for promoting resource resilience while enhancing mechanical performance. This research advances resilient composite design by precisely selecting feedstock, reinforcement loading, and process parameters to optimize compatibility and structural performance. This work investigates microalgae as a promising feedstock due to its low lignin content and favorable thermal degradation profile, enabling the production of biochar with engineered microporosity through controlled pyrolysis. To further enhance the biochar’s performance, post-pyrolysis treatments, such as silanization and core-shell rubber (CSR) particle synthesis, were investigated to improve matrix compatibility and strengthen the interfacial bonding with the thermoplastic resin. Additionally, to overcome dispersion challenges and prevent particle agglomeration, a three-roll mill technique is employed, ensuring uniform nanoscale distribution of biochar within the resin. This integrated approach supports scalable thermoplastic composite processing, paving the way for the broader application of engineered biochar in high-performance automotive components.