Tag: materials

Sustainability-In-Tech : New Class Of Sustainable Bacteria-Made Textiles

Posted on by Paul Stradling

London-based biomaterials company Modern Synthesis has unveiled a new class of nonwoven materials derived from ‘bacterial nanocellulose’.

Sustainable Alternative To Other Materials

These innovative textiles can be made to replace everything from plastic films to leathers, thereby offering a sustainable alternative to some of the fashion and automotive industries’ most environmentally damaging materials.

Who Is Modern Synthesis?

Founded by former Adidas designer Jen Keane and biomaterials specialist Ben Reeve, Modern Synthesis is an emerging leader in the development of next-generation textiles that move beyond petrochemical and animal-derived materials. The company, headquartered in London, is focused on harnessing bacterial nanocellulose to create a versatile range of fabrics that are not only high-performance but also fully biodegradable.

Keane, now CEO, came into the spotlight in 2018 when she successfully ‘grew’ a shoe using bacteria, demonstrating the potential of biofabrication. However, she believes the true potential lies not in shaping materials as they grow, but in using bacterial cellulose as a foundational fibre that can be manipulated and scaled like traditional textiles.

What is this New Material and Why is it Significant?

Modern Synthesis’ material is primarily made from bacterial nanocellulose, i.e. a natural fibre that is eight times stronger than steel when produced at the nanoscale (materials measured in nanometres, typically less than 100 nm). Unlike plant-based cellulose (which requires intensive farming, land, and water), bacterial nanocellulose is cultivated through fermentation. This makes it a highly efficient and sustainable alternative.

What sets Modern Synthesis apart is its proprietary process, which integrates bacterial nanocellulose with a woven or knitted textile scaffold. This method allows the final material to be fine-tuned for different textures and mechanical properties, making it possible to replace synthetic leathers, coated fabrics, and even high-performance technical textiles.

Unlike most bio-based leather alternatives (which often rely on synthetic binders to achieve durability), Modern Synthesis’ process is entirely free from petrochemicals. The result is a fully biodegradable material that behaves much like conventional textiles but with a significantly reduced environmental footprint.

How is the Material Made?

The production process is an advanced form of microbial fermentation. The company uses a strain of bacteria known as Komagataeibacter rhaeticus, which naturally produces nanocellulose when fed with agricultural sugars. As the bacteria grow, they deposit nanocellulose fibres around a specially designed yarn scaffold, resulting in a unique, nonwoven textile structure.

This controlled approach allows for the fine-tuning of material properties, such as flexibility, strength, and texture, by adjusting the bacterial growth conditions and the composition of the scaffold. Unlike synthetic textiles that require chemical treatments to achieve similar properties, Modern Synthesis’ materials develop these characteristics organically.

Environmental and Industry Implications

The implications for both the fashion industry and the wider materials market could be vast. For example, leather and synthetic textiles, such as polyurethane-based vegan leathers, are major contributors to greenhouse gas emissions, plastic pollution, and deforestation. The carbon footprint of Modern Synthesis’ bacterial nanocellulose-based textiles is expected to be significantly lower than that of both traditional leather and synthetic alternatives.

Water usage is another key area of impact. Traditional leather production requires thousands of litres of water per square metre, whereas bacterial nanocellulose fermentation uses a fraction of that amount. Also, Modern Synthesis’ material does not involve toxic tanning chemicals, further reducing its environmental impact.

For businesses, this innovation could offer a way to meet growing consumer demand for sustainability without sacrificing quality or performance. Luxury brands and sportswear companies have already shown interest, with Danish fashion house Ganni collaborating with Modern Synthesis in 2023 to create a handbag made entirely without petrochemicals.

Potential Applications

Beyond fashion, Modern Synthesis’ materials have potential applications in:

– Footwear. As a lightweight, durable replacement for leather and synthetic uppers.

– Automotive interiors. The material’s high-temperature resistance and durability make it an attractive option for dashboards and upholstery.

– Smart textiles. The company is exploring how nanocellulose can be integrated with electronics for wearable technology.

Keane has highlighted the versatility of the material, stating, “Cellulosic materials don’t melt like synthetics do. If you think about car dashboards, how they start to warp when left in the sun too long—our materials won’t do that.”

Challenges and Limitations

While Modern Synthesis’ technology seems promising, there are still many hurdles to overcome before widespread adoption. For example, the company recognises that scaling production to meet industrial demand remains a major challenge. With this in mind, the company is currently working to increase production at its pilot facility fivefold, but larger-scale manufacturing will require further investment and infrastructure.

Another challenge is recyclability. While the material is biodegradable, ensuring it is also recyclable without compromising its durability remains a key focus. Many bio-based materials require additional treatments that can hinder their ability to be repurposed at the end of their life cycle. Modern Synthesis is understood to be actively working with “green chemistries” to develop formulations that balance performance with circularity.

Who Else is Developing Similar Materials?

Modern Synthesis is actually part of a growing movement towards microbial-based textiles. Other players exploring bacterial nanocellulose include:

– MycoWorks, which specialises in mushroom-derived mycelium leather.

– Bolt Threads. Developed Mylo, another mycelium-based leather alternative.

– Ananas Anam, the creators of Piñatex, a plant-based leather alternative derived from pineapple leaves.

However, most of these alternatives still require synthetic binders, whereas Modern Synthesis’ approach stands out for being entirely bio-based and customisable at the nanoscale.

What Does This Mean For Your Organisation?

Modern Synthesis’ bacterial nanocellulose-based textiles could be an important advancement in the quest for sustainable materials. By leveraging microbial fermentation to create high-performance, biodegradable fabrics, the company is offering an alternative that challenges both traditional leather and synthetic textiles on environmental grounds. Unlike many bio-based alternatives that still rely on petrochemical additives, this new class of material is not only renewable but also fully biodegradable, making it a compelling solution for industries seeking to reduce their ecological footprint.

However, while the potential is undeniable, challenges remain. Scaling up production to meet commercial demand is a critical hurdle, as is ensuring the material can be seamlessly integrated into existing supply chains. Also, achieving true circularity (i.e. where the material is not just biodegradable but also efficiently recyclable) will be essential in determining its long-term impact. Modern Synthesis appears to be actively addressing these concerns, but success will likely depend on continued innovation and investment.

What appears to set Modern Synthesis apart is not just its scientific approach but its vision for redefining how materials are made. By collaborating with major fashion brands and exploring applications beyond apparel, the company is positioning its technology as a viable replacement for some of the most environmentally damaging materials in use today. If production challenges can be overcome, bacterial nanocellulose textiles could play a key role in reducing reliance on fossil fuels, lowering carbon emissions, and transforming industries that have long been dependent on resource-intensive materials.

This innovation could, therefore, offer a promising glimpse into the future of sustainable manufacturing. While it may take time to achieve widespread adoption, the foundations are being laid for a possible material revolution and one that moves beyond extraction and towards biofabrication. If Modern Synthesis and others in the field can bridge the gap between laboratory breakthroughs and large-scale industry use, bacterial nanocellulose textiles could become a defining material of the sustainable era.

Sustainability-in-Tech : Revolutionary Material Absorbs Over 99% Of Light

Posted on by Paul Stradling

Researchers at the Korea Institute of Materials Science (KIMS) have developed a composite material capable of absorbing more than 99 per cent of electromagnetic waves across multiple frequencies.

Could Transform Many Industries

In an era where technology and sustainability must progress hand-in-hand, the ground-breaking ultra-thin, flexible film could transform industries ranging from energy and telecommunications to defence and environmental health, perhaps marking a major milestone in sustainable materials science.

What Is This New Material?

The researchers achieved this breakthrough by synthesising a unique magnetic composite material and incorporating it into a polymer film with double-sided conductive patterns. Three critical components underpin the material’s success:

– Magnetic Composite Layer (MCL). Synthesised by altering the crystal structure of ferrites, this layer exhibits strong ferromagnetic resonance (FMR) properties, enabling high absorption of electromagnetic waves at specific frequencies.

– Conductive Patterned Grid (CPG). Designed as a precisely engineered filter, the grid transmits electromagnetic waves at certain resonant frequencies while minimising reflection.

– Double-Walled Carbon Nanotube Film (DWCNTF). This film works as the primary absorber, dissipating the trapped waves through conduction losses and enhancing overall shielding effectiveness.

Together, these layers create a material that is not only ultra-thin and flexible but also robust enough to withstand 5,000 bending cycles without compromising performance. Its flexible nature makes it ideal for emerging technologies such as foldable smartphones, rollable displays, and wearable devices.

What Makes This Material Special?

The new material developed by KIMS researchers is so special because it essentially redefines electromagnetic interference (EMI) management with its ultra-thin, flexible design (less than 0.5 mm thick) and an extraordinary ability to absorb over 99 per cent of electromagnetic waves from sources like 5G/6G communications, Wi-Fi signals, and radar systems. Unlike conventional shielding materials, which reflect waves and inadvertently create secondary interference, this material captures and dissipates waves, effectively eliminating electromagnetic pollution.

Its dual capability of ultra-low reflectance (less than 1 per cent) and high absorbance across three distinct frequency bands makes it uniquely suited to mitigate electromagnetic pollution while enhancing the performance of devices reliant on electromagnetic waves. This contrasts sharply with traditional materials, such as metals and carbon-based films, which achieve high shielding through reflection but suffer from inefficiency, secondary pollution, and limitations in high-frequency applications like millimetre-wave (mmWave) technologies.

By adopting an absorption-dominant approach, the KIMS material converts electromagnetic waves into heat or dissipates them through conduction losses, providing a more sustainable and effective solution. As Senior Researcher Byeongjin Park explains, “Conventional shielding materials reflect over 90% of electromagnetic waves, with an absorbance often as low as 10%. Our new composite overcomes these limitations by absorbing and eliminating electromagnetic waves entirely, significantly improving the reliability of wireless communication devices.”

Key Features and Benefits

The composite material’s features and benefits extend far beyond traditional shielding technologies. These include:

– Triple resonant absorption. The material demonstrates ultra-low reflection and high absorption at three distinct frequency bands, including frequencies used in 5G communication, autonomous vehicle radar systems, and wireless gigabit communication. It achieves a total shielding effectiveness (SET) of 70 dB (equivalent to 99.99999 per cent shielding) with less than 1 per cent reflection.

– Flexibility and durability. Its thin, lightweight design ensures easy integration into next-generation devices, while its durability allows repeated folding and bending without degradation, making it ideal for applications in rollable electronics.

– Wide frequency coverage. The material works across mmWave frequency bands, which are critical for advanced communications and radar technologies.

– Environmental advantages. By absorbing rather than reflecting electromagnetic waves, it mitigates secondary interference and electromagnetic pollution, reducing both environmental and health concerns.

Potential Applications

The implications and applications of this material are vast, potentially offering solutions across numerous industries while addressing key sustainability challenges. For example, these could include:

– Enhancing renewable energy systems. The material’s ability to absorb and manage electromagnetic waves efficiently could significantly improve the performance of renewable energy systems. For instance, integrating it into solar panels might allow the capture of a broader spectrum of light, increasing energy conversion rates. Also, it could be used in solar thermal systems to better harness and store energy as heat.

– Revolutionising consumer electronics. With the rapid growth of IoT devices, wearables, and flexible electronics, the demand for compact, efficient EMI shielding solutions has never been higher. This material could ensure these devices operate without interference, consume less power, and last longer. Imagine a world where your smartphone or smartwatch no longer suffers from signal loss or energy inefficiency due to interference.

– Supporting wireless energy harvesting. Ambient electromagnetic waves from Wi-Fi routers, cellular networks, and radio signals could be captured and converted into usable energy for low-power devices. This could open up possibilities for powering IoT sensors, reducing reliance on batteries, and enabling the development of sustainable smart cities.

– Tackling electromagnetic pollution. The material’s unique absorption properties address the growing concern of electromagnetic pollution, a by-product of our increasingly wireless world. By reducing stray waves in urban areas, it could improve environmental health while boosting the performance of critical communication systems.

– Advancing communication technologies. In telecommunications, managing signal propagation with minimal energy loss is crucial. This material could enhance the efficiency of network infrastructure, reduce data transmission costs, and improve signal clarity for technologies such as autonomous driving and drone communication.

– Defence and security. The material’s ability to absorb electromagnetic waves makes it a natural fit for stealth technology, where radar invisibility is paramount. Beyond military applications, it could be used to safeguard sensitive information by preventing electromagnetic eavesdropping.

– Industrial efficiency. From optimising microwave-based manufacturing processes to enhancing heat dissipation in high-performance electronics, this material offers ways to reduce energy consumption and improve the efficiency of industrial operations.

– Sustainable building design. Its heat absorption capabilities could be leveraged in construction, where it might enable passive heating solutions. By capturing and releasing heat as needed, it could reduce dependence on artificial heating and cooling systems.

Why This Innovation Matters for Sustainability

Beyond its immediate technical merits, this material represents a step towards more sustainable technologies. By enhancing energy efficiency, reducing electromagnetic pollution, and supporting the development of cleaner electronic devices, it aligns with the global push for greener, more responsible innovation.

Also, the researchers’ focus on scalability ensures its accessibility for widespread application. The material has already been patented in multiple countries and licensed to domestic manufacturers, with plans to integrate it into real-world devices and systems.

Dr Byeongjin Park summarised its significance: “This material has the potential to transform how we think about electromagnetic wave management. As 5G and 6G communications expand, so too does the need for materials that can improve device reliability and minimise environmental impact. Our innovation is a step forward in achieving these goals.”

What Does This Mean For Your Organisation?

The development of this composite material could represent a significant step forward in both materials science and sustainability. Its innovative ability to absorb over 99 per cent of electromagnetic waves while remaining ultra-thin, flexible, and durable appears to make it uniquely positioned to address some of the most pressing challenges in technology and environmental health.

This material’s absorption-dominant design directly confronts the longstanding issues associated with traditional EMI shielding, such as secondary electromagnetic pollution and inefficiency at higher frequencies. By converting unwanted electromagnetic waves into heat or dissipating them entirely, it reduces interference, enhances device performance, and contributes to the reliability of critical technologies like 5G/6G communications, autonomous vehicles, and IoT devices. The fact that it achieves this while being less than 0.5 mm thick and resistant to wear from repeated bending is nothing short of remarkable.

What truly sets this breakthrough apart, however, is its potential for wide-ranging applications. From revolutionising renewable energy systems to tackling the growing concern of electromagnetic pollution, this material stands out as potentially being a versatile solution with real-world impact. For example, its role in enhancing wireless energy harvesting could redefine urban sustainability, while its ability to improve energy efficiency in consumer electronics and industrial processes offers an opportunity to significantly reduce waste and resource consumption.

Also, the material’s potential in defence, secure communication, and sustainable construction illustrates its adaptability across diverse fields. Its capacity to absorb electromagnetic waves for stealth purposes, enhance thermal management in buildings, and even optimise industrial manufacturing processes demonstrates its vast applicability. Each of these use cases highlights how the material aligns with the global shift towards technologies that not only perform better but also contribute to sustainability goals.

The researchers’ efforts to ensure scalability and accessibility further highlight the importance of this innovation. By licensing the technology for practical applications and securing patents internationally, the KIMS team hopes to have laid the groundwork for integrating this material into mainstream industries. Such a forward-thinking approach may ensure that its benefits can be realised on a global scale, potentially making it a true enabler of sustainable progress.

In a world increasingly reliant on electromagnetic wave-based technologies, the need for efficient, environmentally friendly solutions is critical. This composite material looks as though it not only addresses that need but does so in a way that could open the door to a new era of sustainable innovation. Looking ahead, as its adoption expands, it has the potential to redefine industries, improve energy efficiency, and reduce the environmental footprint of modern technology.

Sustainability-in-Tech : New 3D Printer Automatically Identifies Different Sustainable Materials

Posted on by Paul Stradling

There’s an increasing range of renewable and recyclable materials now available yet 3D printers have historically been limited by the need to create new parameter sets for each one. However, MIT researchers have now made a 3D printer that can automatically identify the parameters of unknown materials on its own.

Overcoming The Parameter Limitations 

The problem with having to 3D print a new material from scratch up until now has been that typically at least 100 parameters must be set up in the software which controls how the printer will extrude the material as it fabricates an object. The materials commonly used for 3D printing (e.g. mass-manufactured polymers) already have established sets of parameters (that were only perfected through lengthy trial-and-error processes).

Now, with the need to use more renewable and recyclable materials (the properties of which can fluctuate widely based on their composition) making fixed parameter sets in the 3D printer for each one is nearly impossible to create, with the only option to date being users having to set all the parameters by hand.

However, researchers at the Massachusetts Institute of Technology (MIT) appear to have solved this problem by developing a 3D printer that can automatically identify the parameters of an unknown material on its own.

How? 

The new 3D printer is able to work out the parameters for different materials thanks to a modified extruder which can measure the forces and flow of a material. A load cell measures the pressure being exerted on the printing filament, and a feed rate sensor measures the thickness of the filament and the actual rate at which it is being fed through the printer.

The data gathered by the new extruder (via the load cell and feed rate sensor, in a 20-minute test) can then be fed into a mathematical function that is used to automatically generate printing parameters. The parameters can then be entered into off-the-shelf 3D printing software and used to print with a never-before-seen material.

In experiments with six different materials, several of which were bio-based, the new 3D printer was able to automatically generate viable parameters that consistently led to successful prints of a complex object.

As lead researcher Neil Gershenfeld, pointed out: “The goal is to make 3D printing more sustainable”. 

Opens The Door For More Recycled and Bio-based Materials 

Looking ahead, as noted by Alysia Garmulewicz, an associate professor in the Faculty of Administration and Economics at the University of Santiago in Chile: “By developing a new method for the automatic generation of process parameters for fused filament fabrication, this study opens the door to the use of recycled and bio-based filaments that have variable and unknown behaviours. Importantly, this enhances the potential for digital manufacturing technology to utilise locally sourced sustainable materials.” 

Also, the researchers have said that they will be applying their discovery in other areas of advanced manufacturing, as well as in expanding access to metrology (the scientific study of measurement).

What Does This Mean For Your Organisation? 

This discovery by the MIT researchers could be a significant advancement for businesses looking to embrace green manufacturing practices. This breakthrough not only saves time (and money) and simplifies the 3D printing process but also offers the potential for companies to innovate in ways that are both economically and environmentally sustainable.

For businesses, the implications of this technology go far beyond the mere convenience of automation. This printer could enable the use of a wider range of renewable and recyclable materials, significantly reducing dependency on traditional, often non-sustainable materials. As a result, organisations may be able to lower their environmental impact and align more closely with evolving regulations and consumer expectations regarding sustainability.

The ability of this printer to handle materials with variable and unknown behaviours also opens the door to using more locally sourced materials. This could be particularly beneficial for businesses aiming to reduce their carbon footprint by minimising the logistics associated with transporting materials. Also, it enhances the potential for creating more personalised and localised products, catering to specific market demands with greater agility.

The discovery of this new 3D technology could also bring further innovations in digital manufacturing. It may help businesses to explore new product designs and applications without the extensive time and cost previously involved in trial-and-error parameter setting. This may not only accelerate product development but may also make small-scale, bespoke production runs more feasible and cost-effective.

Crucially, the incorporation of more recycled and bio-based materials into mainstream manufacturing processes, facilitated by this new technology, could help more businesses contribute to a circular economy. This shift may help conserve natural resources and also open up new business opportunities in the recycling sector. Companies that can efficiently convert waste into valuable printing materials may be more likely to thrive in an increasingly resource-conscious market.