This project explores the potential market opportunities and applications for a novel bamboo fiber-reinforced composite material with bio-HDPE matrix. The research, conducted in collaboration with Eve Reverse, focuses on developing a thermoplastic composite with aligned short bamboo fibers to enhance mechanical properties in specific directions, allowing for programmable strength. The goal is to research the desirability of the new carbon-negative bio-based short fiber composites and designing its appropriate application.
The project adopts the Material Driven Design (MDD) method, combining experiential characterization studies, mechanical testing, together with prototyping to assess the composite’s desirability, feasibility, and viability.
The testing of the bamboo fiber composite's mechanical properties, including its stiffness and strength, which showed comparable performance to traditional materials like plywood. Experiential characterization studies involved a series of observation-based experiments, questionnaires, and interviews to gather insights on potential consumers' perceptions and emotional responses to the material.
The results indicated that the bamboo fiber composite material offers a natural, warm aesthetic that elicited positive emotional feedback from users, including feelings of comfort and curiosity. These findings are crucial for establishing the desirability of this material in the marketplace, as they demonstrate consumer interest in products made from sustainable materials. Despite some concerns about the material's sustainability, it offers a compelling alternative for eco-conscious consumers.
The design vision can be concluded from mapping the findings of material characterization and market research. Following the vision, with the help of ideation groups, the idea of ceiling fan blade perfectly fit the vision and the requirement. Prototyping and functional testing further confirmed the feasibility of using bamboo composite materials The study validated vacuum bag thermoforming as an effective manufacturing method for producing smooth, uniformly thick bamboo composite blades capable of complex curves. The project also explored the feasibility of remanufacturing a multi-layer plate by pile up bamboo composite which demonstrated the potential for producing larger composite structures. Finally, from a viability perspective, the project aligns with the increasing demand for carbon-neutral products in the European Union, with legislation likely to support the development of sustainable materials. The result of quick LCA proved the sustainability impact is relatively low from cradle-to-gate calculation. The easy accessibility of raw materials, and relatively simple manufacturing process ensure it can be produced affordably while maintaining profitability. In the future, bamboo fiber composite has great potential to realize a low-cost automatic production line, with the combination of environmental sustainability and economic efficiency, providing bio-based thermoplastic materials in the market as a sustainable alternative.