Bioplastics S04299 Structure, Material, Tectonics and Space S01525 Digital Design and Full Scale Fabrication Andrei Gheorghe Wolf Mangelsdorf Florian Medicus
Group 4 Allen Bell Tam-Anh Nguyen Barbara Krajcar Mihaela Carpov Zhongzheng Zhang
WS 2023-2024
What is a bioplastic? Bioplastics are eco-friendly materials made from renewable sources like vegetable fats, corn starch, wood, and recycled food waste. They can be derived directly from natural biopolymers or synthesized chemically from sugar derivatives and lipids. The recipe for biodegradable bioplastics typically includes a biopolymer, plasticizer, and solvent. Using materials such as starch and cellulose instead of fossil fuels makes bioplastics production more sustainable. The environmental impact of bioplastics is debated based on various metrics, including water use, energy use, and biodegradation. However, overall, bioplastic production reduces greenhouse gas emissions and non-renewable energy consumption.
Apparatus and Ingredients SetUp To prepare bioplastics, you will need various apparatus and equipment depending on the specific type of bioplastic you intend to produce. Here‘s a general overview of the apparatus commonly used in the preparation of this particular bioplastic: measuring cup/cylinder
pot
electric stove
glycerol mixing vessel
water gelatine
electric scale
stirring tool
Ingredients Gelatin is the biopolymer in the mixture. It is a protein derived from animal collagen and acts as the structural component of the bioplastic. It forms a network of chains that give the material its strength and flexibility when solidified. Water acts as the solvent in this case. It is used to dissolve the gelatin and create a solution. The gelatin dissolves in water when heated, forming a homogeneous mixture. The water provides a medium for the gelatin molecules to disperse and interact, allowing for the subsequent solidification process. Glycerol serves as the plasticizer. Glycerol is added to the mixture to enhance the flexibility and elasticity of the bioplastic. It works by disrupting the intermolecular forces between gelatin chains, preventing them from sticking together too tightly. This results in a more pliable and stretchable material. You can also explore the potential of bioplastics by incorporating a medley of organic materials, including fruit and vegetable skins, leaves, flowers, or eggshells, into your creations.
Recipe and preparation There are several recipes to create bioplastics. For this particular experiment, we‘ve used three basic ingredients: gelatine, glycerol, and water. Additional recipes can be found at the end of the book. • • • • •
cold water gelatine glycerol additives food coloring (optional)
200 ml 48 g 12 g 8g 10 g
1. Mix the cold water and the gelatine in a pot, without heating. 2. Whisk them together until the mixture transforms into a granular, pale yellow paste. 3. Heat over medium heat, stirring continuosly, until the gelatine is fully dissolved. 4. Once the mixture has become liquid and homogeneous, add the glycerol and continue stirring until the mixture starts to thicken or simmer. 5. For a transparent finish, use a spoon to skim off any froth, ensuring the bioplastic achieves a glossy and smooth surface. Alternatively, if you desire a textured appearance, leave the froth within the mixture. It will dry on the surface of the bioplastic, creating fluffy parts. 6. Secure a wooden frame or a nonstick mold with tape and pour the solution into it. 7. Allow the bioplastic to air-dry completely. 8. Once dry, carefully remove the bioplastic from the frame or mold. Note: • Bioplastics containing higher levels of glycerol exhibit increased flexibility, whereas those with lower glycerol content tend to be more brittle. • The drying time depends on several factors: the quantities of water, gelatine and glycerol used in the mixture, the thickness of the final product, as well as room‘s temperature and humidity. It‘s best to let dry the bioplastic for 2-3 days before taking it off. Removing it too early may lead to deformation, as the bioplastic may continue drying even after removal.
Additives: Organic materials
hokaido pumpkin, coarsely ground
avocado skin, teared by hand
lemon skin, finely shredded
clementine skin, teared by hand
avocado skin, teared by hand
carrot, coarsely ground
eggshell, coarsely ground
avocado skin, finely shredded
onion skin, teared by hand
Additives: Organic materials
aubergine, peeled and cut
avocado pit, coarsely shredded
butternut pumpkin, peeled
carrot skin, peeled
clementine skin, finely ground
avocado pit, finely ground
hibiscus, teared by hand
pomegranate flowers
nettle leaves, coarsely ground
Process
gelatine and water in a vessel no mixing
gelatine mixed with water until a homogeneous mixture is formed
gelatine mixed with water until a granular, pale yellow paste is formed
mixture transfered into a pot
mixture is heated up and the gelatine starts to melt
mixture has become liquid glycerol and clementine peel are added
mixture starts to thicken and simmer froth is formed on the surface
solution is poured into a mold
dried and flexible bioplastic
Outcome
thin and flat structure, smooth surface neutral smell
flexible and resistent to bending translucent, with additive particles here and there
multiple flat bioplastics can be laid over, so that a more rigid structure is formed
due to a thicker layer of poured solution, the bioplastic has formed mold
due to an increased amount of organic additives, the bioplastic shrinks faster and deforms
brittle, cannot be bent has a funky shape
better connectivity between the ground eggshell particles
thicker than the bioplastics with fruit or vegetable peel additives, no mold
brittle, can be broken if bent
Observations • Bioplastics can take any shapes, including volume, surface, and sheets. • While cooking the mixture, it emits an unpleasant odor. However, once the bioplastics are dried, the smell fades away. • Bioplastics exhibit adhesive properties and adhere to wood surfaces. When casting, it is advisable to pour the mixture onto a non-porous base such as glass or plastic, particularly acrylic. • To create flat bioplastic sheets, pour the bioplastic mix into a wooden frame, allow it to dry, and then remove the sheets from the frame. • Bioplastics can be recycled by breaking them into small pieces, heating them with water until they dissolve, and then recasting them into a new form. • Due to their low melting points as thermoplastics, prolonged exposure to sunlight can cause bioplastics to deform. • While bioplastics lack water resistance and may deform when exposed to rain or moisture, this characteristic also makes them biodegradable. • To enhance water resistance, incorporate wax into the bioplastic solution. • Biocomposites can be created by adding fibers, minerals, or food waste to bioplastic recipes. • Expect bioplastics to shrink as water evaporates during the drying process, with those containing a lower percentage of glycerine more prone to shrinking. • If bioplastics are cooler than the ambient temperature, they are still in the drying process. • Casting thick bioplastics may lead to molding; to prevent this, cover them with a textile to keep the bioplastic clean.
Bioplastics as Formwork Material A formwork is a temporary structure used as mold for the original structure. There are different materials available to construct the formwork. Formwork material is selected depending upon many factors like cost, requirement, type of structure etc.
Plastic is another type of formwork material which is used for small concrete structures or for complex portions of the structure. It is light in weight and durable for long periods. For complicated concrete structures, Glass reinforced plastics (GRP) and vacuum formed plastics are used. Advantages • • • •
Plastic is light in weight and can be easily handled. Formwork for complex shaped structures can be prepared easily. Good resistance against water. The damaged plastic sheets can be recycled and useful to make new sheets, great re-usability.
Disadvantages • Plastic is weak against heat. • It is a costly material. • It does not take much load when compared with others.
The Plastic Formwork System offers a construction approach for cast-in-place reinforced concrete structures. It enables the rapid construction of house walls, taking as little as a day, utilizing locally sourced materials and involving unskilled laborers, all while minimizing waste.
The system consists of square plastic components that interlock to create wall panels for assembling the house. The infrastructure of the house, including steel-reinforcement bars, conduits, window and door frames, pipes, and other fittings, is positioned on the wall. Once in place, these elements are enclosed by a second layer of panels, creating a cavity into which lightweight concrete mortar is poured. After the mortar sets overnight, the Plastic Formwork panels are dismantled and reused at the next housing site, reducing waste and transportation requirements. Each plastic formwork kit can be reused for casting up to fifty homes. After reaching this limit, the plastic is recycled into everyday consumer products like toilet seats. This approach results in homes that are resilient to natural disasters, provide thermal insulation, and resist moisture. Furthermore, it fosters local job creation without compromising quality or structural integrity. The Plastic Formwork System has been successfully implemented in housing projects across South Africa, and the company has expanded its presence to thirteen countries, including Namibia, Mozambique, and Mexico.
Dissolving Brick Arch: Rain Reveals Mortar Skeleton Designed by stpmj, the Dissolving Arch is a weather-responsive installation tailored to South Korea‘s Island Jeju‘s tropical environment. Originally a solid brick vault, the structure gradually dissolves during the island‘s hot and rainy seasons, transforming into a delicate, porous skeleton crafted from the residual mortar. This unique process connects people with nature, reflecting the island‘s distinctive character. The project concept originates from the designers‘ fascination with the materiality of brick and structure. The installation predominantly utilized rock-salt units, distinguished by their translucency and solubility. Each brick, measuring 200 x 100 x 50 millimeters, was integrated with a cement mortar during construction. The process involved scoring one side of each rock-salt brick to ensure adhesion to the mortar, reinforced by steel wires. Initially, the Dissolving Arch formed a dense, solid object with enclosed rock-salt bricks creating an impervious structure. Despite the initial seclusion, the space was illuminated by delicate streams of light filtering through the rose-colored units. Over the course of the three-month exhibition, the rain and humidity of Jeju Island caused the dissolution of the rock-salt bricks, ultimately revealing only the mortar skeleton. With the structure allowing more light in and fostering a connection with nature, the ambiance within the space underwent a gradual transformation.
stpmj aspired to initiate a dialogue where a solid, isolated object, initially concealed from its environment, could evolve into a luminous, airy structure fostering a connection with nature. In contrast to conventional clay brick, rock salt does not absorb mortar moisture, resulting in a smooth rather than a rough, frictional surface for the remaining structure. The ultimate form of the Dissolving Arch permits light penetration, blurring the boundaries between the interior and exterior.
ArboSkin Bioplastic Facade Architects and designers are using a blend of biomaterials, including activated charcoal, gelatin-based bioplastics, and recycled plastics, to craft designs that not only enhance the visual appeal of facades, but also have the potential to reduce air pollution. An innovative project at the University of Stuttgart‘s ITKE has resulted in a groundbreaking 90% bioplastic facade prototype, showcasing significant strides in both recyclability and renewability. Developed collaboratively by a team of designers, researchers, and academics, the material, known as ArboBlend, serves as the cornerstone for the creation of ArboSkin, a triangulated facade material. Engineered by Tecnaro, ArboBlend comprises over 90% bio-polymers and less than 10% inorganic mineral compounds designed for UV protection. Notably, the bioplastic eliminates halogens, chlorines, bromines, and keeps oil-based components and additives to a minimum, streamlining the recycling process.
In production, the bioplastic undergoes formation into granules, which are then extruded into sheets for versatile processing. These 3.5mm thick sheets can be adapted through drilling, printing, lamination, laser-cutting, CNC milling, or thermoforming, yielding diverse surface qualities and structures for various molded components. The facade mock-up, based on a triangular mesh blueprint, serves as a tangible illustration of the architectural applications of this innovative bioplastic. Each mesh element, composed of bioplastic pyramids or panels with thermo-formed relief, contributes to the structural integrity of the design. In this freeform facade, the bioplastic functions as a sheet material, forming a shell-based structure with additional load-bearing and bracing components. This design approach leverages the loadbearing properties of the doubly curved skin as the primary bracing element for the entire system, setting it apart from conventional non-load-bearing facade constructions. Ultimately, this advancement allows us to soon offer thermo-formable bioplastic sheets, presenting a product that meets the increasing demand for resource-efficient and sustainable building materials. The vision is for these sheets to emerge as a highly efficient alternative, combining the adaptability and recyclability inherent in plastics with additional environmental benefits derived from predominantly renewable resources. This aligns with the rise of buildings featuring double-curved geometries and planar facades, emphasizing 3D effects.
Aectual ‘s Sustainable 3D Printed Floors Aectual is carrying forward the Dutch tradition of 3D construction printing, which originated with the 3D Printed Canal House in 2013. The Amsterdam-based technology company recently introduced a sustainably produced 3D printed floor with terrazzo infill at the latest Dutch Design Week. Aectual‘s smart manufacturing technology enables the custom 3D printing of any design on large surfaces, ensuring each square meter is unique. Rather than focusing on large-scale projects like 3D printed airport floors, the company emphasizes creating custom designs for spaces like hotel lobbies or distinctive retail brands, providing designers with complete freedom. Hans Vermeulen, CEO of Aectual, states, „We make it possible to create custom designs for spectacular floors, giving designers complete design freedom.“ Clients can choose from a range of special patterns tailored to their building, allowing for the addition of unique details to highlight specific areas, branding, and routing.
With roots in the 3D Printed Canal House project, Aectual has evolved its approach, shifting from plastics to composites and foams. The company‘s ‚on demand floor‘ is facilitated by in-house developed software tools and industrial XL 3D print technology. This approach streamlines the design and production process, reducing installation periods and making it easy, affordable, and reliable for clients. The 3D printed patterns of Aectual‘s floors are seamlessly installed on-site and finished with a bio-binder terrazzo, offering a wide range of color options and fillings. Notably, the floors are produced sustainably, using bio-print plastic and recycled materials. Aectual‘s clientele includes international museums, hotels, and department stores. Following its launch at the Loft Flagship store in Tokyo, the first floor in the Netherlands is scheduled for installation at Amsterdam Schiphol Airport in mid-November. During Dutch Design Week, Aectual showcased its unique digital production process and various floor patterns, including the design for the Schiphol floor by architecture firm DUS. The company marked its official launch with the ‚Democratizing Design Debate,‘ featuring well-known architects and designers discussing the impact of digital technology on design, including figures like Winy Maas from MVRDV and Jelle Feringa from Aectual.
Bibliography ArboSkin Bioplastic Facade: https://www.dezeen.com/2013/11/09/arboskin-spiky-pavilion-with-facademade-from-bioplastics-by-itke/ https://urbannext.net/arboskin-bioplastic-facade/ https://materialdistrict.com/article/thermoformable-bio-plastic-developed/ Dissolving Brick Arch: Rain Reveals Mortar Skeleton: https://www.archdaily.com/880691/this-brick-arch-installation-dissolves-in-the-rain-to-leave-a-mortar-skeleton Bioplastics as Formwork Material: https://inhabitat.com/plastic-formwork-system/ https://theconstructor.org/building/materials-formwork-advantages-disadvantages/6188/
Aectual ‘s Sustainable 3D Printed Floors: https://www.voxelmatters.com/aectual-lives-3d-printed-floor/ Additional Recipe and Information: https://materiom.org/search https://materiability.com/portfolio/bioplastic-robotic-materialisation/ https://issuu.com/kasandraba/docs/bioplastic_pavilion https://issuu.com/nat_arc/docs/the_secrets_of_bioplastic_ https://issuu.com/nat_arc/docs/bioplastic_cook_book_3