Abstract
Chitin is an abundant naturally produced biomaterial, a primary constituent in exoskeletons of arthropods. Chitosan, produced via deacetylation of chitin, is a unique biomaterial which exhibits unique mechanical and chemical properties such as chelation and affinity to materials like cellulose and metals. Chitosan solution forms thin films when dried, and exhibits a significant shrinkage, especially in the "z" dimension (hence thin films). Precedent research has developed techniques to produce functional products from chitosan thin films, the natural form of chitinous natural structures, but three-dimensional objects require mixing with other components such as cellulose and silica. This study investigates how chitosan combined with metals can form a functional three-dimensional material. The hypothesis is that the natural properties of chitosan will enhance its bonding with metal to produce a bio-inspired chitosan-metal composite. Further innovation and applications for such a material are explored via the Ideate, Prototype, Realise approach. A tin-based novel bio-composite was discovered, which can be cast and manufactured into three dimensional structures and can be post-processed mechanically and thermally to exhibit functional mechanical/electrical properties. The capabilities and production methodology of the composite are demonstrated by producing a component via non-energy-intensive additive manufacturing methods and is functionally like a metallic material. These findings highlight the capabilities of chitosan as a material and the possibility of cold manufacture of metallic components via additive manufacturing.