Developing poplar wood into a green structure-decoration integrated material for prefabricated wooden building application

Fast growing poplar wood poses significant challenges including low mechanical strength, poor dimensional stability and weak texture, limiting its direct application in the field of building structures and decoration. We treated poplar wood using compression, digital printing and waterproofing techniques to develop a green structure-decoration integrated material. The compression treatment significantly improved the wood density, fiber orientation and surface smoothness. At a compression ratio of 60%, poplar veneer demonstrates remarkable improvements in modulus of elasticity (MOE), modulus of rupture (MOR) and surface smoothness, with increases of 222.53%, 233.53% and 93.20%, respectively, compared to uncompressed wood. Notably, this compression treatment reduces the surface roughness of poplar to 0.75 μm, meeting the flatness requirements for digital printing. Consequently, clear textures and vibrant colors are directly printed onto the flat surface of compression-densified poplar wood, eliminating the need for traditional surface sanding pre-treatment process, and accordingly improving the efficiency of the material preparation. Furthermore, a final waterproofing emulsion spraying treatment creates a dense micro/nanoscale hierarchical structure on the surface, enabling the compression-densified poplar wood samples to achieve MOE and MOR of 14.15 GPa and 123.00 MPa respectively, even after water absorption and re-dried processes. These values consistently exceed the standard value of MOE (12.50 GPa) and MOR (35.00 MPa) for the highest grade (TCT40) specified in GB50005-2017, indicating significantly improved structural stability. The structure-decoration integrated materials developed in this study offer high strength and dimensional stability, making them promising candidates for high value utilization in prefabricated wooden buildings.