Seaweed farming 3D printed structures using new generation alternative binders: a novel interdisciplinary approach, from computational fluid dynamics to life cycle assessment.

In March 2023, the EU Parliament adopted a new carbon sink target that raises climate ambition by increasing the EU's carbon sink capacity by 15% by 2030.

Seaweed farming has huge potential to sequester carbon dioxide, but the current state of the art raises questions about the cost and environmental effectiveness of such a structure.

A new alternative solution of vertical marine printed algae farms, made of an alternative material and with limited impact on the marine ecosystem, can solve these problems.

The research plan, based on interdisciplinary aspects combining two approaches, consists of a three-scale study related to computational rheology, and of a two-scale investigation related to Life Cycle Assessment.

The development of printing technology and a newly developed in-line powder-fluid mixer brings the possibility of less impactful material processing with an industrial mindset.

To generalise such a complex processing issue raised by alternative binders and enable topology optimised design, novel numerical simulation approaches need to be developed to link experimental models with computational fluid dynamics simulations.

Underwater 3D printing of such complex materials also raises very novel issues, closely related to the opening of cracks that compromises the aesthetics and durability of 3D printed materials.

The goal of reducing the carbon footprint and the use of raw materials can be achieved through two strategies: the first is to reduce the amount of material for a given application thanks to the 3D printing of optimised structures, while the second is related to the Life Cycle Assessment of alternative materials and to give an overview of the benefits along the entire value chain of the seaweed farming structure during its service life, from ingredient production to waste management.

This case study raises topical issues that still need to be addressed in terms of process simulation, structural design of complex structures and life cycle assessment.