7. BioFabricating Materials

Creating biomaterials involves exploring sustainable and innovative ways to develop materials using biological components. This week, we’ll be diving into techniques that transform natural resources into usable materials, potentially leveraging bio-based polymers, plant fibers, or microbial cultures. Through careful experimentation with biological ingredients and processes, we’ll aim to achieve unique material properties such as biodegradability, flexibility, and resilience. This approach not only promotes eco-friendly alternatives but also pushes the boundaries of material design by tapping into the inherent properties of living organisms.

Research

WHAT IS BIOMATERIALS?

Biomaterials are naturally sourced, organic materials that offer sustainable, environmentally-friendly alternatives to synthetic options by collaborating with nature, helping to minimize waste and reduce environmental harm.

In this class, we’ll concentrate on learning about and creating biomaterials as substitutes for unsustainable materials like plastics. By utilizing local resources and traditional methods, we strive to encourage a more circular approach to design and manufacturing.

SCARLETT YANG

Scarlett Yang, a graduate of Central Saint Martins, designed an innovative dress made from algae extract and silk cocoon protein that pushes the boundaries of sustainable fashion. Her creation has a glass-like appearance and unique properties that allow it to grow organically over time. Remarkably, this material is designed to fully decompose in water within just 24 hours, leaving no trace. Yang's work exemplifies the potential of biomaterials to combine aesthetics with eco-consciousness, demonstrating how biodegradable, natural elements can be harnessed to create dynamic and environmentally friendly fashion pieces.text

References & Inspiration

Watching Scarlett Yang's dress unfold must have felt like witnessing the spirit of nature embodied in fabric—a fusion of beauty, transience, and renewal. Feeling called to work with nettle resonates deeply with this, as if the plant itself is guiding your hands. There’s something profoundly touching about connecting with materials that speak to us, carrying the spirit of the earth in every fiber and reminding us of the life within the things we create.

Making bioprastic

WHAT IS BIOPRASTIC?

Bioplastic is a type of plastic made from renewable biological sources, such as plants, algae, or microorganisms, instead of fossil fuels. Unlike traditional plastics, which are derived from petroleum, bioplastics are created using materials like corn starch, sugarcane, or even algae, making them potentially more sustainable and less harmful to the environment. Some bioplastics are biodegradable or compostable, breaking down naturally under certain conditions, while others mimic traditional plastic durability.

However, not all bioplastics are compostable or biodegradable, so understanding the properties of each type is important to ensure its eco-friendly potential.

The AGAVOCAR recipe, created by Anastasia Pistofidou of Fab Lab Barcelona and Director of Fabricademy, is an accessible and sustainable approach to creating bio-based materials using avocados and agave. Designed with simplicity in mind, this recipe provides clear, straightforward instructions that allow users to transform everyday organic waste into valuable biomaterials. By repurposing agave and avocado waste, AGAVOCAR embodies the ethos of circular design, promoting sustainable practices in material creation. Ideal for makers, designers, and eco-enthusiasts, this recipe highlights how natural resources can be reimagined into functional, eco-friendly materials that carry unique textures and colors.

Overview material research outcomes

Material	Recipe	Feeling
1 Tapioca foil	Tapioca	transparent, sticky, shiny
2 Tapioca resin (dried with bubbles)	Tapioca	translucent, hardened
3 Mango + tapioca leather	Mango + Tapioca	translucent, shiny from certain angles
4 Gelatin resin (with flowers)	See tutorial video	reflective, transparent, capturing, smooth
5 Gelatin resin (casted on matte lining)	Gelatin	matte, blurring, hidden
6 Alginate composite with sand	Alginate	sandy
7 Alginate composite with sand for handprinting	Alginate	sandy
8 Agar cubes with coffee	Agar	opaque, wobbly
9 Agar sheet	Agar	translucent

Process and workflow

MANGO BIOLEATHER

Recipe Template

Developed by Loes Bogers for her Fabricademy 2019/2020 final project.

Physical Properties

Form: Solid, Surface

Natural Color (without additives): Translucent, yellow to orange-brown hues.

FABRICATION TIMELINE

Preparation Time: 1 hour

Processing Duration: Approximately 1 week

Detailed Drying Schedule

Initial Drying: 14 hours in an oven at a low temperature (40–50°C with fan setting).

Extended Drying: Alternate between air drying and pressing every 8 hours over the next 5 days. Outdoor drying can speed up the process if conditions are dry and sunny.

Final Form Achieved In: 7 days

This recipe template was developed by Loes Bogers as part of her final project in Fabricademy 2019/2020. Through careful experimentation, she created a comprehensive guide to crafting bio-based materials, focusing on sustainable and accessible techniques. Her template provides a structured approach to achieving specific colors, textures, and forms, allowing for a reproducible process that yields consistent results. Loes’s work reflects a commitment to eco-conscious material design, serving as a valuable resource for anyone interested in innovative biomaterial fabrication text

Ingredients & Recipes

Prepare this recipe by collecting the ingredients necessary, to be found in the list below:

INGREDIENTS

• 2 Overripe mangoes - with skin: get these as waste from the market, they can have dents and bruises it doesn't matter.

• 1 lemon

• Beeswax: 20g

• Cinamon: 1 teaspoon

TOOLS

1. Cooker or stove: (optional: temperature controlled)

2. Pot

3. Blender or stick mixer

4. Scale

5. Oven or a Dehydrator machine :that can go as low as 50 degrees (or ideally 40) with ventilation

6. Mould or flat surface :you can cast the fruit leather into a shallow mould with wals (need not be higher than 5 mm) or cast directly onto a smooth sheet. Applying some oil helps to release it. Make sure it fits into your oven

7. Spoon or squeegee

METHODS

Mango Preparation

Cut the mango into small pieces and blend it into a smooth puree.

Beeswax Preparation

Chop the beeswax into smaller pieces to ensure it melts evenly when heated.

Combining Ingredients

1 In a pot, combine the mango puree with lemon juice and chopped beeswax.

2 Heat gently on low, stirring constantly to prevent sticking and bacterial growth. Avoid boiling; allow some water to evaporate if the mixture is too thin.

3 After about 20 minutes, the mixture should reach a thick but pourable consistency suitable for casting.

Casting and Oven Dehydration

1 Pour and spread the paste onto a flat surface or mold, tapping the mold on a hard surface to level it.

2 Preheat the oven to 50°C with the fan setting, then place the mold inside for at least 16 hours. If needed, break up the drying time over a few days, letting the paste air dry in between sessions.

3 To aid moisture escape, keep the oven door slightly open with a cloth.

4 Once dried, remove the leather carefully, flip it over, and check the bottom. If it’s still damp, return it to the oven with the moist side facing up for additional drying.

Air Drying

1 When the leather feels dry and slightly darkened, leave it to air dry in a well-ventilated area for 5–7 days.

2 Alternate pressing under heavy books or drying with a weighted rack to keep the leather flat during the curing process.

Drying and Curing

1 Mold Depth: Use a 3 mm depth mold with acrylic borders.

2 Shrinkage: Thickness may reduce by 50%, and width/length by around 5%.

3 To Manage Shrinkage/Deformation: Allow up to 7 days for complete drying. Factors such as juice content can affect the drying rate; removing too early may damage the leather.

Using Release Agents

A light layer of oil can help release the leather from the mold more easily.

Minimum Wait Time

Wait at least 2 days before demolding.

Post-Processing

1 Trim rough edges and shape the leather while still pliable for clean results.

2 Store finished leather in a dry area, with baking paper between sheets to avoid sticking. Adding desiccants, such as starch, can help maintain dryness.

Additional Experimentation

Consider adjusting the water evaporation rate during drying or incorporating more starch. Experiment with post-treatments to improve water resistance; refer to the “variations on this recipe” for further ideas.

After blending the mango with lemon juice and a hint of cinnamon, the mixture takes on a warm, golden hue with a subtle aroma that combines the sweet, tropical scent of mango with the zesty brightness of lemon and the comforting spice of cinnamon. The consistency is smooth and slightly thick, ideal for further processing. The added cinnamon not only enhances the fragrance but also deepens the color slightly, giving the puree a rich, inviting appearance. This blend is now ready for the next step in the recipe, bringing a unique flavor profile and natural color to the final product.

After blending, transfer the mango, lemon, and cinnamon mixture into a pot and set it over low heat. Stir continuously for about 20 minutes, allowing the flavors to meld and the mixture to thicken slightly. The gentle heat helps evaporate some of the moisture, concentrating the mango’s sweetness and enhancing the mixture's color to a deeper golden-orange. Be careful not to let it boil, as that could affect the texture and taste. By the end of 20 minutes, the mixture should have a thicker, slightly glossy appearance, making it perfect for casting or further processing.

Documenting and comparing experiments

TEST SERIE BIO-PLASTIC

RESULTS

After two days, my bioplastic experiment has finally taken shape, revealing interesting textures and qualities. The material has set and started to show unique characteristics, such as translucency, flexibility, and a smooth surface, with slight imperfections that give it an organic feel. Observing its drying process over time has been insightful, as it allowed me to understand how the material stabilizes and hardens. This result has sparked ideas for how bioplastics can be further used in my projects, especially in exploring sustainable alternatives with natural aesthetics.

After allowing the material to dry for up to seven days, I carefully observed the results to manage any shrinkage or deformation. The drying time can vary depending on factors like the juice content, which influences how quickly moisture evaporates. Removing the material too early risks damaging its structure, as it may not have fully hardened or stabilized. By patiently monitoring the process, I ensured that the final texture maintained its intended properties, avoiding any unintended warping or cracking. The extended drying time proved essential in achieving a durable, flexible finish suitable for further use or handling

ALGINATE STRINGS

GENERAL INFORMATION

A strong, springy or flexible cord (depending on the diameter of the extruder), alginate-based. The cord is strong and flexible and is somewhat comparable to thick nylon or rubber. It is more flexible than nylon but stiffer than rubber.

Physical Form

Strings

Color

Without Additives: Matte white, translucent

Fabrication Time

Preparation Time:

1 hour (plus resting overnight)\

Processing Time: 5-7 days Attention Needed:

Every few hours on the first day to spray additional curing agent and rearrange the strings.

Final Form Achieved After

Total Time: 7 days

RECIPE

Ingredients

Sodium alginate powder - 6 gr

the polymeer (so it becomes a solid)

Glycerine - 10 gr

the plasticizer that bonds with the alginate (makes it flexible).

Water - 200 ml/gr

to dissolve and mix the polymeer and plasticizer

optional: use a (diluted) natural dye instead for a colored plastic

Sunflower oil - 5 gr

filler to reduce shrinkage

Calcium chloride solution 10% - 300 ml (30 gr to 300 gr water)

is the curing agent: calcium chloride attracts moisture very strongly: spraying it onto the alginate plastic starts the curing process.

---

1. recipe: salmon skin fish-leather ↩