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Despite national and international regulations, plastic microbeads are still widely used in personal care and consumer products (PCCPs) as exfoliants and rheological modifiers, causing significant microplastic pollution following use. As a sustainable alternative, microbeads were produced by extrusion of biomass solutions and precipitation into anti-solvent. Despite using novel blends of biodegradable, non-derivatized biomass including cellulose and Kraft lignin, resulting microbeads are within the shape, size, and stiffness range of commercial plastic microbeads, even without crosslinking. Solution processability and resulting bead shape and Young’s modulus can be tuned via biomass source, concentration, and degree of polymerization; biomass concentration, extrusion geometry, and precipitation and extraction conditions control the bead size. Lignin incorporation reduces the solution viscosity, which improves processability but also produces flatter beads with higher moduli than cellulose-only microbeads. While some lignin leaches from the beads when stored in water, adding surfactants like sodium dodecyl sulfate suppresses this effect, resulting in good mechanical stability over 2 months with no noticeable structural degradation. The stability of these mixed-source biomass microbeads—despite the absence of chemical crosslinking or derivatization—makes this route a promising, robust approach for obtaining environmentally-benign microbeads of tunable size and stiffness for use in PCCPs. 

Abstract Extensional flow properties of polymer solutions in volatile solvents govern many industrially-relevant coating processes, but existing instrumentation lacks the environment necessary to control evaporation. To mitigate evaporation during dripping-onto-substrate (DoS) extensional rheology measurements, we developed a chamber to enclose the sample in an environment saturated with solvent vapor. We validated the evaporation-controlled DoS device by measuring a model high molecular weight polyethylene oxide (PEO) in various organic solvents both inside and outside of the chamber. Evaporation substantially increased the extensional relaxation time$$\lambda _{E}$$ ${\lambda }_E$for PEO in volatile solvents like dichloromethane and chloroform. PEO/chloroform solutions displayed an over 20-fold increase in$$\lambda _{E}$$ ${\lambda }_E$due to the formation of an evaporation-induced surface film; evaporation studies confirmed surface features and skin formation reminiscent of buckling instabilities commonly observed in drying polymer solutions. Finally, the relaxation times of semi-dilute PEO/chloroform solutions were measured with environmental control, where$$\lambda _{E}$$ ${\lambda }_E$scaled with concentration by the exponent$$m=0.62$$ $m=0.62$. These measurements validate the evaporation-controlled DoS environment, and confirm that chloroform is a good solvent for PEO, with a Flory exponent of$$\nu =0.54$$ $\nu =0.54$. Our results are the first to control evaporation during DoS extensional rheology, and provide guidelines establishing when environmental control is necessary to obtain accurate rheological parameters.