Innovations Addressing Material Waste In Engineering

How Butterflies help us to transform Sewage Sludge into Next-Gen 3D Printing Materials Every year, millions of dry metric tons of sewage sludge, an organic-rich byproduct of wastewater treatment, pose a huge disposal challenge and environmental burden. Traditionally destined for incineration, landfills, or limited agricultural use, this overlooked resource is now getting a second life through innovative material science! We developed a method to harness hydrothermal processing (HTP) to convert wet sewage sludge into hydrochar, carbonaceous solid that can be further activated. Unlike typical biomass, sewage sludge contains unique metallic and metalloid dopants. These impurities lead to surprising outcomes during thermal activation: instead of the expected boost in carbon content and improved graphitic ordering, the process actually decreases carbon ordering, creating a distinct material structure with its own set of properties. When incorporated into 3D printing resins, this hydrochar acts as a sustainable filler. Initially, it may compromise stiffness and hardness due to limited resin-filler adhesion. However, by adopting nature-inspired gyroid geometries, designs reminiscent of butterfly wings and bird feathers, the composite’s toughness and elongation can not only be recovered but enhanced! This integration of bio-inspired architecture overcomes inherent material weaknesses and paves the way for eco-friendly prototypes, packaging, and beyond. 1️⃣ Diverting millions of tons of sludge from landfills and incineration reduces greenhouse gas emissions and pollutant dispersion. 2️⃣ Incorporating waste-derived hydrochar in 3D printing reduces reliance on raw synthetic materials, promoting a circular economy and sustainable manufacturing. 3️⃣ The synergy between material science and bio-inspired design opens new horizons for advanced composites with tailored properties through innovative design. This fusion of waste valorization, unconventional chemistry, and cutting-edge design showcases a transformative path toward sustainable manufacturing. Read more details in the paper (open access): Sabrina Shen, Branden Spitzer, Damian Stefaniuk, Shengfei Zhou, Admir Masic, Markus J. Buehler, Communications Engineering, Vol. 4, 52 (2025), https://lnkd.in/eBeESHJY

🏗️ Growing the Future: 3D-Printed Mycelium Imagine buildings that grow, self-repair, and decompose naturally when no longer needed. Researchers have developed a 3D-printing method for mycelium biocomposites, eliminating the need for molds and unlocking new possibilities for sustainable, biodegradable materials. Using spent coffee grounds as a substrate, this innovation turns waste into strong, compostable structures—a game-changer for packaging, architecture, and beyond. 🤓 Geek Mode Traditional mycelium-based materials require molds, which limit design flexibility. This study introduces: Mycofluid: A 3D-printable mycelium paste made from 73% spent coffee grounds. Fungibot: A custom extruder that prints living biomaterial. Mycostructure: A process where printed parts grow together, fusing into seamless, self-supporting structures. By fine-tuning viscosity, growth conditions, and extrusion techniques, the team produced mechanically robust biocomposites. The printed objects self-colonize with fungi, creating hydrophobic surfaces that resist water while retaining biodegradability. 💼 Opportunity for VCs This technology offers a paradigm shift in materials science. It opens doors for: - Sustainable packaging that replaces polystyrene. - Biodegradable furniture and structures that grow and adapt. - Self-healing biomaterials for modular, repairable buildings. - Carbon-negative manufacturing with hyper-local supply chains. VCs investing in biofabrication, circular economy, and sustainable construction should take note—this is the frontier of regenerative materials. 🌍 Humanity-Level Impact Instead of mining, melting, or molding, we can grow what we need: 1️⃣Carbon-neutral cities, where buildings decompose instead of turning into waste. 2️⃣Mars-ready habitats, using fungi to construct and self-repair in extreme environments. 3️⃣A circular bioeconomy, where waste (like coffee grounds) fuels innovation. This isn’t just eco-friendly tech—it’s nature’s blueprint, optimized for modern fabrication. 📄 Link to original study: https://lnkd.in/gQNsTVEP #DeepTech #VentureCapital #Biomaterials #3DPrinting #CircularEconomy

Biocycling: Using 3D imaging to transform plastic waste recycling. University of Waterloo researchers have used 3D imaging to understand the fine details of microplastics, paving the way for more effective methods of plastic waste recycling. Canada. September 05, 2024 Excerpt: In collaboration with National Research Council (NRC), researchers leveraged 3D imaging technology in addition to traditional 2D microscopy, to observe degradation of micro and nanoplastics with unprecedented detail. "Most microscope images provide a two-dimensional view, similar to a medical X-ray, which provides some information but lacks depth," said William Anderson, a professor in Waterloo’s Department of Chemical Engineering. "3D imaging is like a CT scan, offering far more detailed insights into the structure and degradation of microplastics. This level of detail has been challenging to achieve, but it's crucial for understanding what is happening at the surface of micro and nanoplastics and how degradation processes work." The research group used a novel combination of physical and biological approaches to obtain new visual data. They utilized a photocatalytic process, which treated micro and nanoplastics with UV light and a titanium oxide catalyst. The team was able to observe and analyze degradation at a microscopic level. "Using this methodology reveals not just that degradation is happening, but exactly how and where it's occurring on the surface of micro and nanoplastics, said chemical engineering professor Boxin Zhao, a University of Waterloo Endowed Chair in Nanotechnology. “This knowledge is crucial for developing more effective methods of breaking down plastics on the micro and nanoscales.” Note: Anderson and Zhao, in collaboration with researchers from the Department of Chemical Engineering and the Department of Biology at Waterloo, are developing biocycling methods where microplastics could be used as a carbon source for bacteria. The bacteria would ingest microplastics and then excrete an environmentally friendly biopolymer that could be used to create new materials like plastic bags or packaging films. This study has broader implications for Waterloo’s research team, which is now forming a multidisciplinary plastics biocycling research initiative. The collaboration underscores the importance of bringing together different fields of expertise to tackle complex environmental challenges. This research offers valuable insights that could pave the way for more effective methods of plastic waste recycling and contribute to a circular economy. Publication: IOP Science | Nanotechnology 12 July 2024 3D imaging photocatalytically degraded micro-and nanoplastics https://lnkd.in/e6P42e2a https://lnkd.in/e95Cexbr