Complex Geometry Cellulose Hydrogels Using a Direct Casting Method

To facilitate functional hydrogel part production using the indirect wax mould method, it is necessary to understand the relationships between materials, process and mould removal. This research investigated the thermophysical properties, wettability and surface roughness of wax template moulds in the production of cellulose hydrogel objects. Cellulose gel was thermally formed and shaped in three different wax moulds—high melting point paraffin, sacrificial investment casting wax and Solidscape(®) wax—by physical cross-linking of polymer networks of cellulose solution in NaOH/urea aqueous solvent. All three wax moulds were capable of casting cellulose hydrogel objects. Cellulose gelling time was reduced by increasing the temperature. Thus, the mould melting temperature had a direct effect on the gelling time. It was found that mould removal time varied based on the contact angle (CA) of the cellulose solution and the mould, and based on the melting point of the mould. A higher CA of cellulose solution on the wax moulds resulted in faster mould removal. When melting the wax in 90 °C water, high melting point paraffin, sacrificial investment casting and Solidscape(®) wax took about 3, 2 and 1.5 h, respectively, to remove the moulds from the cellulose gel.