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Process

Ideation & sketches

Growing up in a rural area, I saw my sister and others struggle with the cost and lack of sanitary products. Fabricademy sparked my passion for textiles, leading me to explore sustainable materials like banana fibers. This project is about rethinking materials to solve real problems and create sustainable solutions.

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Design & Fabrication

_Step 1: Extracting and Processing Banana Fibers Estimated Time: 1-2 days 1.1 Extraction of Banana Fibers Materials Needed: • Fresh banana pseudostems • Sharp knife or scraper • Water • Bucket or soaking tank Process: 1. Harvest the Banana Pseudostems : Cut down banana stems (pseudostems) after harvesting bananas 2. Peel the Outer Layers: Remove the hard outer layers and extract the soft, inner layers. 3. Scraping Method: Use a knife or mechanical scraper to separate fibers manually. 4. Retting: Soak the fibers in water for 12-24 hours to loosen them naturally. 5. Drying: Air-dry the extracted fibers for 6-12 hours in shade to avoid weakening.

Step 2: Softening and Enhancing Absorbency of Banana Fibers Estimated Time: 1-2 days 2.1 Chemical Treatment for Softening Fibers Materials Needed: • 5% NaOH (Sodium Hydroxide) solution or eco-friendly alternative: baking soda solution • Water • Heating system • Stirring rod • Gloves & safety glasses Process: 1. Prepare a 5% NaOH Solution – Mix 50g of NaOH in 1 liter of warm water. 2. Soak Fibers – Submerge the banana fibers in the solution for 4-6 hours to break down lignin and improve softness. 3. Rinse & Neutralize – Wash thoroughly with clean water and soak in 2% acetic acid (vinegar) for 30 minutes to neutralize excess alkali. 4. Drying – Air-dry fibers for 12 hours in shade. 2.2 Bleaching (Optional, for Lighter Fibers & Better Absorption) Materials Needed: • 3% Hydrogen Peroxide (H₂O₂) or eco-friendly bleaching agents (lemon juice + sunlight) • Water • Bucket Process: 1. Soak Fibers in 3% H₂O₂ for 4-6 hours to lighten the color. 2. Rinse & Dry – Wash with water and dry in indirect sunlight for 8-10 hours.

Step 3: Enhancing Absorption for Menstrual Blood Estimated Time: 2-3 days 3.1 Superabsorbent Treatment Materials Needed: • Sodium Carboxymethyl Cellulose (CMC) or Agar Gel • Distilled water • Heating system Process: 1. Prepare Gel Solution – Dissolve 2-5g of CMC or agar in 100mL of warm water until it forms a gel. 2. Coat Fibers – Soak banana fibers in the gel for 4-6 hours to improve absorption. 3. Dry & Test Absorbency – Air-dry fibers for 12-24 hours, then test by dropping simulated menstrual fluid on them. Alternative Absorbent Boosters: You can also add biodegradable hydrogel made from aloe vera, alginate, or pectin.

Step 4: Assembling the Biodegradable Sanitary Pad Estimated Time: 1 day 4.1 Layering the Pad Structure A typical sanitary pad has three layers: 1. Top Layer (Comfort Layer) – Fluid Transfer Materials: Organic cotton, bamboo fiber, or banana fiber textile Process: Cut fabric into rectangular or oval shapes (20cm x 8cm). Ensure it’s breathable and allows fluid to pass through easily. 2. Core Layer (Absorbent Layer) – Banana Fiber Core Materials: Processed banana fibers from Step 3, extra cellulose fibers (optional for boosting absorption) Process: Stack 2-4 layers of banana fiber for absorption. Press and shape fibers to match the top layer dimensions (20cm x 8cm). 3. Bottom Layer (Leak-Proof Layer) – Eco-Friendly Barrier Materials: Cornstarch bioplastic, wax-coated paper, or biodegradable polymer sheet Process: Cut a waterproof layer slightly larger than the absorbent core. Attach it using an eco-friendly adhesive or heat pressing.

Step 5: Testing & Quality Assurance Estimated Time: 2 days 5.1 Absorption Rate Test Materials: • Simulated menstrual blood (saline mixed with gelatin or blood analog) • Dropper Process: 1. Drop 5mL of simulated blood onto the pad every 30 seconds. 2. Measure how much liquid the core retains without leaking. 3. Compare to commercial pads. 5.2 Leakage Test Process: 1. Place a 10mL soaked pad on a flat surface with paper underneath. 2. Observe after 5 minutes if there is any leakage. 5.3 Biodegradability Test Process: 1. Bury a used pad in moist soil or compost. 2. Check decomposition progress every week for 30-60 days.


This step was crucial as I worked on extracting, processing, and enhancing banana fibers to improve their softness and absorption. After assembling the biodegradable sanitary pad by layering the materials, I began testing its performance, refining the design with each prototype


Prototypes

prototypes are your first step towards shaping your final piece, product, material et cetera


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Mentoring notes

Mentors in all sessions may share with you their comments, notes, advise, projects and technical equipment to check out. This is good place to share those, so that you can find them later on when you need them the most!

Half-fabrication files

  1. Test file: 3d modelling test ↩