Freeform monolithic graphitic aerogels by laser pyrolysis of pretreated blood-derived feedstocks

While 3D-printed graphitic aerogels (GAs) offer broad applications, existing manufacturing methods face limitations in scalability and material performance. This study presents a two-step laser pyrolysis strategy for the rapid direct manufacturing of freeform monolithic GAs using hemoglobin, a renewable biowaste-derived feedstock. Through targeted precursor pretreatment and digitally controlled laser processing, ultralightweight GAs with interconnected ultrathin sheets and denser strut-like boundaries are produced. Despite their low density, these GAs exhibit remarkable properties owing to their high graphitic crystallinity and seamless architecture, achieving rapid and stable Joule heating with superior efficiency (∼137.43°C W⁻¹), ideal for de-icing applications. The programmable laser process enables geometry-customizable fabrication, allowing material and energy-efficient design optimization for next-generation automotive and aerospace systems. This work highlights the critical role of transient-state control in tuning structure-property relationships and establishes pretreatment as a powerful yet underexplored strategy for scalable sustainable manufacturing of high-performance architected carbon materials from renewable feedstocks.