Form Follows Fiber - a Case Study for a Low-Carbon Bioplastic Chair: Prototyping Methods for Greener Manufacturing

Abstract

Since the industrial revolution, manufacturing practices have prioritized speed and the financial bottom line, rather than the health of the environment and its inhabitants. Industry’s over-extraction of natural resources, open-loop production models, and the reliance on fossil fuels have led to skyrocketing carbon emissions and the proliferation of toxic waste. A selective transition to bioplastics presents significant opportunities for curbing emissions and landfill loads. Bioplastics are derived from renewable resources, rather than petroleum, and break down into soil components and water. When blended with crop fiber, an abundant waste product of agriculture, they make resilient composites that can displace the plastics and monoculture lumber in engineered timber. Historically, the chair has been the platform to experiment with new means of production in a discourse over emerging technologies and novel materials. In this case study, an ergonomic task chair is built from scratch using experimental biomaterials and digital prototyping methods. It is free from petroleum ingredients, made from 100% renewable materials, completely compostable, and has a fraction of the footprint of conventional competitors. This showcase features samples of the Chair and a presentation of its prototyping and methods of manufacture. I share lessons learned sourcing, processing, and molding the ingredients, results from early sample testing and life cycle assessments, and applications for where this practice can go in the future.

Presenters

Jason Carley
Assistant Professor of Industrial Design, Industrial Design, University of Notre Dame, Indiana, United States

Details

Presentation Type

Innovation Showcase

Theme

Architectonic, Spatial, and Environmental Design

KEYWORDS

Sustainability, Biomaterials, Bioplastics, Industrial Design, Furniture, Manufacturing