Bird-nest inspired cellulose-based biofoam with excellent performance enabled by gas–liquid interface co-assembly and thermal welding for plastic replacement

Traditional plastic foam, typically derived from fossil fuel-based polymers that are resistant to natural degradation, faces environmental challenges. As an alternative, cellulose, a biodegradable polymer, shows promise in the production of eco-friendly foam. Nonetheless, its reliance on hydrogen bonding between fibers poses limitations for practical applications. Here, drawing inspiration from bird nest structures, a straightforward and scalable method (co-assembly and thermal welding) has been developed for creating cellulose-PLA biofoam. The resulting biofoam displays advantageous properties such as low density (12.9 ∼ 27.1 kg/m3), high compression strength (modulus of 12.1 MPa·cm3·g−1), good thermal stability, and water stability (maintaining structural integrity in water). Moreover, it exhibits exceptional degradation rates (significant degradation within 40 days) and recyclability. Thus, this biofoam holds promise as a sustainable alternative to standard plastic foams, mitigating "white pollution."