Materials Research

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

e2e Bioc o m p o s i t e U Sto o l Clay, Richard & Zena

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

the next industrial revolution...

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

Initial Provocation

What is TransFORM? “Has the ability to turn corners, shape profiles, even copy intricate designs. We can create solutions with different densities, strengths and surface finishes on one piece. We can consolidate multiple production steps into one.”

“Higher strength-to-weight ratios compared to wood composites... thereby reducing weight and shipping costs.”

-e2e website TransFORM is a thermoformed biocomposite made from soy resisn and grass-fibers. The result is a stronger and lighter alternative to exisiting woodcomposits such as fiberboard or partical board. The process uses no formaldehyde or petrochemicals and use 60% less energy.

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Research

Basic Properties

compostable recyclable weightefficient flame-retardant biodegradable thermoformable e n e r g y - e f f e c i e n t

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Sustainability By using Bagasse appropriate the raw material for free as it is a by product of the sugar production process. In Louisiana around 100,000,000 tons are currently burned in the field or transported to landfills and the e2e process takes advantage of this.

The production process of the e2e material itself uses 60% less energy and water than comprable material Soy Resin is not a new non plastic material. It has been used since the early 20th Century, most commonly known for its use on the Model T Fords. Also Thomas Edison experimented with Soy based resin and concrete in Florida. The composite material is 2 times denser than particle board so the durability will make the material last longer, having more resilience in its environment. It is fire retardant. There is no off gas of the material unlike its counterpart, fiberglass. Appropriate material Bagasse which uses less water to harvest than kenaf and jute, also this material would otherwise be waste. Begasse is a by product of the sugar production process. In Louisiana around 100,000,000 tons are currently burned in the field or transported to landfills and the e2e process takes advantage of this. If the composite material is buried within 60 days it will decompose into the dirt.

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Research

Bagasse & Other Grass Fibers Grass fibers can be used to create ropes and strong textiles, such as burlap. Jute fibers block out UV light, act as insulation for sound and heat, are anti-static, and carbon dioxide neutral. Flax is stronger than cotton and less elastic, making it a good material for twine, rope and printed money. Kenaf is often utilized in the production of insulation and packing materials. It is commonly used to blend with resins for plastics. Grass fibers are relatively easy to grow and do not require much aid from fertilizers.

Jute

Flax

Kenaf

Bagasse

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Research

Material Availibility - Soy based Resin Soy based resins are formaldehyde free, which removes the risk breathing in harmful dust when being processed for various applications.

This also makes consumer products safer as they release less poisonous off-gases into the air. Soy based resins are polymers with a greater intra-chain link, creating stronger bonds.

The soy resin component is what gives the material its particular aroma and is currently an unavoidable characteristic.

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Research

Manufacturing - Thermoforming A process where a combination of the fibre of Bagasse and the powder of the Soy Resin is heated to a pliable forming temperature. The temperature for Gen 3 is 120 degrees, although continuing research and experiments are showing molding temperatures to be as low as 70 or 80 degrees. The molds are made of aluminum and compression happens at 700 psi. After the pressure is applied it takes roughly 6 -8 minutes for the material to set into an extremely dense form. The manufacture parts, they do not assemble. The Manufacturer is roughly 100,000 square feet and utilize only 10 percent.

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Research

Comparable Materials e2e Biocomposite is 2-3 times stronger than existing particle baord at 2-3 times less weight. It has the ability to be formed like a fiberglass without the harmfull resisns or glassfiber dust. Thus it requires significantly less manufacturing ventilation. Although not as strong or waterproof as fiberglass there are many applications where e2e biocomposites would be a cost efective e

Plywood

Fiberglass

MDF

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Current Examples of Use “Our applications can show substantial reductions in the manufacturing process of our customers. Wood is basically flat. Yes, you can cut it and shape it within limits, but doing that increases material costs and waste. Unfortunately, very few products are flat!

It takes time and money to complete the steps to assemble that cabinet, furniture, toy, musical instrument, door panel, casket, molding profile or just about anything else” - (from e2e website)

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

e2e Biocomposite Processing: Injection Molding: No Extrusion: Yes Cold Pressing/Deep Drawing: No Blow Molding: No Thermoforming: Yes Lamination: No Printable: No Stitchable: No Rotomolding: No Weldable: No Wood Working Tools: Yes Die cut: No Metal Working Tools: Yes Castable: No

Sustainability: Biodegradable Biopolymers Non-toxic/non-hazardous Renewable Waste materials

Usage Properties: Cradle to Cradle: N/A Fire resistance: Medium Usage temperature: Low Colorfastness: Medium Wear Resistance: Medium Water Resistance: Medium Acoustics: Sound reflecting Chemical Resistance: Medium UV resistance: Medium Scratch resistance: Medium Outdoor use: Yes Tear Resistance: High Reflectivity: Light absorbing Stain Resistance: Medium Thermal Conductivity: Low Physical Properties Stiffness: Stiff Structure: Closed Impact Resistance: Good Surface/Texture: Matte Transparency: Opaque Surface Hardness: SemihardUsage

Properties: Cradle to Cradle: N/A Fire resistance: Medium Usage temperature: Low Colorfastness: Medium Wear Resistance: Medium Water Resistance: Medium Acoustics: Sound reflecting Chemical Resistance: Medium UV resistance: Medium Scratch resistance: Medium Outdoor use: Yes Tear Resistance: High Reflectivity: Light absorbing Stain Resistance: Medium Thermal Conductivity: Low Physical Properties Stiffness: Stiff Structure: Closed Impact Resistance: Good Surface/Texture: Matte Surface Hardness: SemihardTransparency: Opaque Surface Hardness: Semi-hardUsage

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

Initial Concept - Dual Layer Composite Chair

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

Secondary Materials & Processes

UVMax® DVUV, LLC MC# 6572-01

UV-cured powder coating finishes for wood and medium-density fiberboard (MDF). The process involves first pre-heating the MDF to draw moisture out of the wood which attracts the powder electrostatically. The polymer resin is then sprayed onto the part, followed by a second heating step in a flow oven. The powder coat thickness is 3 – 4 mils (0.08 – 0.1 mm). The final step in the process is a UV-curing step to polymerize the powder coating.

Each heating step takes several minutes, and the entire process is completed in less than twenty minutes. The largest size part that can be produced is 4 x 8 ft (1.2 x 2.4 m). The process is an alternative to heat-cured powder coating processes, painting, or laminating. The UV-curing process is energy-efficient, resulting in 40 – 60% savings over paints or laminates. Sprayed powder is reclaimed for reuse, further contributing to the efficiency of the process.

- From the Material COnnexion Database.

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

Inspiration - Active and Dynamic Sitting

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

Experiments:

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

Initial Design

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

Secondary Materials & Processes

3 Pines Sisal Rope Sirichai Wattana & Sons Co., Ltd. MC# 6264-01

Sisal fiber that is woven and braided into yarn and rope. The fibers are free of chemical processing and are offered in a range of ‘natural’ colors. The yarn diameter ranges from 1.52.0 mm (0.06-0.79 in) and the rope diameter from 4.0 to 36.0 mm (0.16-1.42 in). Both rope and yarn have high tenacity, are resistant to wear and acids and alkalis. They are suitable for both performance (fishery equipment) as well as aesthetic (carpet and gift wrapping) applications.

- From the Material COnnexion Database.

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

Final Concept

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

Fabrication Process

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

Manufacture Plan 1. Source Baggase Fibers and soy resin.

2. Source sencondary materials.

3. Source 3 Pines Sisal or equivelanta & die.

4. Design, Enginer and develope mould for thermoforming.

5. Pre-heat press to 120 degrees.

6. Mix baggase fibers & soy resin into hopper vat.

7. Pour into thermoform press cavity.

8. Press for 6-8 minuites.

9. De-mould U form.

10. Mill and finish.

11. Repeat process set up for extruded dowls forms and extured, cut and finish.

12. Stack & Crate in lots of 20. Use spaces created from U forms to store extruded dowls, 13. Add other kit set components.

14. Assemble & disasemble on site or in showroom with no required tools.

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

Sustainability Statement & Marketing Plan • Sourceing local material, shipping.

• Baggase is waste material.

• Thermoformed = simple process, minimal waste, • Simple forms • Comes apart easily for recycling/ compost • Ships in stacking form.

• Resiliance and increase in health of user.

• Ease of assemblance & no use of embeded fasters.

• Fully compostable

PRODUCTS OF DESIGN MATERIALS

U Stool

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

U Stool

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA

PRODUCTS OF DESIGN MATERIALS

U Stool

E2E BIOCOMPOSISTE: RESEARCH

CLAY, RICHARD, ZENA