Surface densification of a piece of solid wood results in an increase in density and in hardness in the whole or a part of the densified material, and is one of the ways of improving the properties and value of low-density wood species. Despite efforts for many years, mass commercialisation of either bulk- or surface-densified wood products has not yet been achieved. Most of the previously tested densification methods have limitations in terms of processing speed and integration into the largely continuous wood processing chain, which leads to high production costs. Established methods to eliminate the set-recovery rely either on technologically complex close-system methods or on open-system methods that require relatively long periods of high energy input. For this reason, impregnation with adhesives is used in almost all commercially available densified wood products, and none of them have risen above their status of being niche products.

Based on this background, three objectives for this project were formulated: (1) the development of a method for selecting the most suitable wood species for surface densification, (2) showing that surface densification can be carried out in a continuous manner at high process speeds, (3) and researching a fast open-system method to reduce the set- recovery.

The method developed for selecting the most suitable wood species for surface densification was based on Lean principles, and it confirmed the suitability of previously studied wood species, such as Scots pine, spruce and poplar. In addition, several suitable alternatives from different parts of the world and from different types of forest were identified. This suggests a high potential for establishing such wood products on a global market level.

Two studies using a continuous roller press showed that solid wood can be successfully surface-densified at process speeds of up to 80 m min-1, and that some defects, such as knots, are acceptable in the raw material, but the problem of set-recovery could not however be solved.

A screening experiment testing different open-system approaches to reduce the set-recovery highlighted the potential of a novel method using ionic liquids as a plasticiser prior to the surface densification of solid Scots pine. The set-recovery could be reduced to 10%, with the time of high energy input being less than 10 minutes. The Brinell hardness was increased by a factor of 2.7 over that of undensified wood. A study with thermo-gravimetric analysis and digital image correlation showed that the set-recovery almost exclusively happens in the transition zone between the densified and undensified wood cells, where there is less penetration of the ionic liquids.

The work accomplished in this project has successfully addressed several gaps in the field of wood densification, firstly, by employing a continuous surface densification process using a roller press, and secondly, by developing and studying a fast open-system pre-treatment with ionic liquids, which greatly reduces the set-recovery. Research will continue on a new band press, facilitating a swift transfer of knowledge between small- scale studies and the continuous surface densification of production-size wooden boards.