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Renewable & Recyclable Materials

Energy efficient and sustainable manufacturing practices

Sustainable manufacturing involves integrating efficient and eco-friendly practices throughout the entire production and distribution lifecycle and aims to maximize the use of resources, minimize waste, and mitigate environmental impact.  

 

The combination of sustainable manufacturing and clean energy technologies is a strategic response to the intertwined challenges of environmental sustainability, resource conservation, and economic viability. A recent outcome is the design and development of next-generation housing such as the award-winning BioHome.

At MDF, teams are working on a variety of commercially viable solutions to help industry adapt to changing market dynamics, regulatory landscapes, and resource availability while contributing to the success and competitiveness of US manufacturing. 

researcher in front of machine

Circular Supply Chains 

A robust, sustainable supply chain involves the conscientious selection of raw materials, transportation methods, and packaging solutions to minimize the carbon footprint and material waste and promote circular economy principles.  

At MDF, researchers are developing high-performance, bio-based composites as well as high-volume polymer and composite repair, recovery, and recycling practices that can enable resilient circular supply chains. This work investigates the recyclability of non-renewable materials as well as the development of bio-based materials derived from forest products and agricultural waste in tandem with advanced manufacturing processes. 

These new materials are likely to be deployed into applications with complex multi-material products, and advanced technologies are required for the separation and recovery of these materials at end of life. 

pine forest

Regional Material Sourcing

The widespread implementation of bio-based materials strengthens domestic supply chains and regional economies by increasing demand for local feedstocks. This approach in turn enables distributed manufacturing across the nation that benefits communities through the creation of local jobs. 

MDF has partnered with the University of Maine to create the Sustainable Materials and Manufacturing Alliance for Renewable Technologies (SM2ART), which integrates advanced manufacturing practices with Maine’s plentiful forestry resources to reinvigorate the region through science-based approaches. The SM2ART program works with industry partners to transfer technology into sustainable, commercial solutions.   

  • Multiple scale mechanical recycling systems with classification 
  • Real-time collection of energy and mass, monetary (labor) data on large scale shredder system, and integration to modeling systems and custom sensor/hardware development 
  • In-house compounding (twin screw extrusion and pelletizing) and forming processes (AM, CM, IM, thermoforming) available from benchtop to industrially relevant scale 
  • State-of-the-art material characterization facilities to support validation of new processes and pathways  
  • New equipment, sensing capabilities  
  • Life cycle assessment and technoeconomic assessment support 

Recent Impacts

Speedy Material Circularity

MDF collaborated with Airtech Advanced Materials Group to recycle and reuse materials from an old carbon-fiber aerodynamic splitter mold into a new one. The work helped Brumos Racing set a world record for its class at the 2023 Pikes Peak International Hill Climb, demonstrating the potential of 3D printing to enable a circular economy.

Watch this video about the potential of 3D printing to enable a circular economy

Award Winning BioHome

In 2023, the SM2ART team won the CAMX Combined Strength award and the SME Aubin AM Case Study award for the BioHome3D project, the nation’s first 3D printed home made entirely from biobased materials.

Read more about the BioHome3D project

As Strong as Steel

A team designed and 3D-printed a single-piece, recyclable, natural-material “Nfloor cassette panel” that tested to be strong enough to replace construction materials like steel for apartments and condos.

Read more about this novel material

Get in touch

Soydan Ozcan
Group Leader
Sustainable Manufacturing Technologies