Innovative Approaches to Low-Carbon Materials

How Butterflies help us to transform Sewage Sludge into Next-Gen 3D Printing Materials Every year, millions of dry metric tons of sewage sludge, an organic-rich byproduct of wastewater treatment, pose a huge disposal challenge and environmental burden. Traditionally destined for incineration, landfills, or limited agricultural use, this overlooked resource is now getting a second life through innovative material science! We developed a method to harness hydrothermal processing (HTP) to convert wet sewage sludge into hydrochar, carbonaceous solid that can be further activated. Unlike typical biomass, sewage sludge contains unique metallic and metalloid dopants. These impurities lead to surprising outcomes during thermal activation: instead of the expected boost in carbon content and improved graphitic ordering, the process actually decreases carbon ordering, creating a distinct material structure with its own set of properties. When incorporated into 3D printing resins, this hydrochar acts as a sustainable filler. Initially, it may compromise stiffness and hardness due to limited resin-filler adhesion. However, by adopting nature-inspired gyroid geometries, designs reminiscent of butterfly wings and bird feathers, the composite’s toughness and elongation can not only be recovered but enhanced! This integration of bio-inspired architecture overcomes inherent material weaknesses and paves the way for eco-friendly prototypes, packaging, and beyond. 1️⃣ Diverting millions of tons of sludge from landfills and incineration reduces greenhouse gas emissions and pollutant dispersion. 2️⃣ Incorporating waste-derived hydrochar in 3D printing reduces reliance on raw synthetic materials, promoting a circular economy and sustainable manufacturing. 3️⃣ The synergy between material science and bio-inspired design opens new horizons for advanced composites with tailored properties through innovative design. This fusion of waste valorization, unconventional chemistry, and cutting-edge design showcases a transformative path toward sustainable manufacturing. Read more details in the paper (open access): Sabrina Shen, Branden Spitzer, Damian Stefaniuk, Shengfei Zhou, Admir Masic, Markus J. Buehler, Communications Engineering, Vol. 4, 52 (2025), https://lnkd.in/eBeESHJY

What Can We Do with Brick Waste? A Circular Approach Brick waste isn’t just debris—it’s a valuable resource waiting to be repurposed. Instead of sending millions of tons of bricks to landfills, we can reintegrate them into the construction cycle, reducing environmental impact and improving material efficiency. 1. Reuse in Facade Restoration & Construction • Deconstruction, Not Demolition – Salvage intact bricks for historic facade restorations or adaptive reuse projects. • Lime Mortar Separation – Traditional cement mortar reduces reuse potential, but lime-based mortars allow for easier brick recovery. • Architectural Feature Integration – Reclaimed bricks can be used for accent walls, decorative facades, and paving elements. 2. Recycle into Secondary Materials • Crushed Brick Aggregates – Used as a sub-base for roads, drainage layers, or lightweight concrete mixes. • Pozzolanic Additives – Finely ground brick dust enhances cementitious properties, reducing the need for Portland cement. • Clay-Based Insulation Panels – Processed brick fines can be reengineered into high-performance, breathable insulation materials. 3. Innovative New Uses • 3D-Printed Brick Components – Crushed brick powder can be reprocessed and printed into modular bricks for new facades. • Bio-Reinforced Bricks – Mixed with mycelium or hemp fibers, recycled brick can form sustainable, self-healing construction materials. • Carbon-Sequestering Geopolymers – Combining brick waste with alkali-activated binders creates cement-free, low-carbon masonry units. 4. Urban Mining & Circular Supply Chains • Material Passporting – Implement digital tracking of recovered bricks to facilitate reuse. • Citywide Material Hubs – Establish brick reclamation centers where contractors can source reusable masonry. • Deconstruction Incentives – Promote financial and policy-driven initiatives to encourage selective material recovery. Why This Matters • Reduces embodied carbon emissions by up to 80% compared to new brick production. • Cuts landfill waste, addressing the 25+ million tons of annual brick waste globally. • Lowers resource extraction, conserving clay and reducing mining-related deforestation. Brick isn’t just a past material—it’s a future-proof one. Let’s stop seeing waste and start seeing opportunity. #circulareconomy #brickreuse #sustainableconstruction #urbanmining #zerowastebuilding #adaptivereuse #facaderestoration #historicpreservation #brickrecycling #deconstruction #materialreuse #lowcarbonmaterials #greenbuilding #carbonfootprintreduction #sustainabledesign #buildingconservation #reclaimedmaterials #constructionwaste #embodiedcarbon #brickfacades #historicfacades #materialpassporting #geopolymer #crushedbrick #bioreinforcedbricks #netzeroarchitecture #sustainablearchitecture #greeninfrastructure #claybricks #futureofconstruction #lowembodiedcarbon #modularbricks #constructioninnovation #carbonsequestration

🏗️ Growing the Future: 3D-Printed Mycelium Imagine buildings that grow, self-repair, and decompose naturally when no longer needed. Researchers have developed a 3D-printing method for mycelium biocomposites, eliminating the need for molds and unlocking new possibilities for sustainable, biodegradable materials. Using spent coffee grounds as a substrate, this innovation turns waste into strong, compostable structures—a game-changer for packaging, architecture, and beyond. 🤓 Geek Mode Traditional mycelium-based materials require molds, which limit design flexibility. This study introduces: Mycofluid: A 3D-printable mycelium paste made from 73% spent coffee grounds. Fungibot: A custom extruder that prints living biomaterial. Mycostructure: A process where printed parts grow together, fusing into seamless, self-supporting structures. By fine-tuning viscosity, growth conditions, and extrusion techniques, the team produced mechanically robust biocomposites. The printed objects self-colonize with fungi, creating hydrophobic surfaces that resist water while retaining biodegradability. 💼 Opportunity for VCs This technology offers a paradigm shift in materials science. It opens doors for: - Sustainable packaging that replaces polystyrene. - Biodegradable furniture and structures that grow and adapt. - Self-healing biomaterials for modular, repairable buildings. - Carbon-negative manufacturing with hyper-local supply chains. VCs investing in biofabrication, circular economy, and sustainable construction should take note—this is the frontier of regenerative materials. 🌍 Humanity-Level Impact Instead of mining, melting, or molding, we can grow what we need: 1️⃣Carbon-neutral cities, where buildings decompose instead of turning into waste. 2️⃣Mars-ready habitats, using fungi to construct and self-repair in extreme environments. 3️⃣A circular bioeconomy, where waste (like coffee grounds) fuels innovation. This isn’t just eco-friendly tech—it’s nature’s blueprint, optimized for modern fabrication. 📄 Link to original study: https://lnkd.in/gQNsTVEP #DeepTech #VentureCapital #Biomaterials #3DPrinting #CircularEconomy

🌱 New Plant-Based Resin for Next-Gen Wind Turbines 🌱 NREL researchers have developed an innovative 100% plant-based resin for constructing sustainable wind turbine blades. Dubbed PECAN, the resin is made from biowaste instead of oil and has superior stiffness over time compared to traditional materials. Critically, PECAN's unique chemical bonds also enable easy, low-energy recycling. As the US aims to deploy over 2 million tons of blade materials by 2050, the ability to locally break down old blades at wind farms would be a major sustainability breakthrough. After optimizing PECAN in the lab, NREL built and tested a 9-meter prototype blade, demonstrating the resin's readiness to replace petroleum-based counterparts. Widespread adoption would slash emissions and waste while supporting the booming wind power industry's renewable goals. Stay curious! 🌱 #sustainability #windenergy #innovation Research institutions/universities: National Renewable Energy Laboratory (NREL) University of Utah Chen Wang Avantika Singh Erik Rognerud Robynne Murray Grant Musgrave Morgan Skala Paul Murdy Jason DesVeaux Scott Nicholson Kylee Harris Richard Canty Fabian Mohr Alison Shapiro David Barnes Ryan Beach Robert Allen Gregg Beckham Nicholas Rorrer https://lnkd.in/gggmbJzC

Excited to share our latest article! In this work, we showed pathways to functionalize biochar using our previously identified biomimetic molecules. This approach allows for incorporating up to 30% (by binder weight) biochar in cement mortar without compromising performance compared to the control batch (without biochar). Highlights include: - Carbon-Neutral Mixes: Using approximately 23% functionalized biochar (by binder weight), we achieved carbon-neutral workable mixes with a compressive strength of 54 MPa, which is 22% higher than the control mix. The carbon footprint (GWP) calculation also accounted for CO2 emissions associated with biochar production. - Carbon-Negative Mixes: Carbon-negative mixes were produced using 30% functionalized biochar or lower dosages in combination with CO2 curing. These mixes exhibited similar strength and adequate workability compared to the control batch. We’ve filed a patent for this innovative approach. If you're interested in commercializing this technology or implementing it in your construction projects, please reach out! We’d be happy to collaborate and can share additional unpublished data under an NDA. Thanks to National Science Foundation (NSF) for funding this work. And to my PhD students for their dedicated efforts: Nishad Ahmed Farzana Mustari Nishat Adhora Tahsin https://lnkd.in/gVymPKip #Biochar #sustainability #carbon-neutral/negative

As trade dynamics shift and tariffs reshape supply chains, construction companies must rethink how they source materials, balance costs, and integrate sustainable solutions. On today's Earth911 podcast, I talked with Grant Quasha of Eco Material Technologies, who returns to the show to share an update. Since his last appearance in October 2023, the company has made significant strides—including securing an $800 million Green Term Loan Facility, which will significantly accelerate the development and adoption of low-carbon cement alternatives. With goals to double production to 20 million tons per year, Grant and his team are working to redefine how we build the world around us. Hear what sustainable business sounds like when a green product makes its case on economic terms. Adopting green materials becomes a no-brainer decision when they are cheaper and better (because pozzolanic concrete lasts longer) and deliver the sustainability consumers want. Grant explains the potential for using low-carbon concrete to build low-income housing, for which Americans are in severe need due to a shortage of 7.1 million affordable housing units. #decarbonization #lowcarbonconcrete #builtenvironment https://lnkd.in/dD7XH-h9

🔄 I love how this diagram realistically shows us that it's time to rethink carbon: From a pure Climate Liability to a Potentially Sustainable Feedstock Instead of seeing CO2 solely as a problem, we must recognize it as a necessary feedstock for our economy. What we need to solve for is how to innovate the sourcing. 🌍 Let's face it. The Carbon Reality: Carbon is everywhere—it’s essential for: ✅ Materials (plastics, carbon fiber, construction) ✅ Chemicals & fuels ✅ Agriculture & food production ✅ Pharmaceuticals & consumer goods The issue? Most of this carbon still comes from fossil fuels. We need sustainable alternatives to power the next industrial revolution. 📊 The Rise of the Sustainable Carbon Economy: New research highlights three key pathways for sourcing carbon responsibly: 1️⃣ Biological Carbon 🌱 Capturing CO2 through photosynthesis Converting it into biomass, biochar & biofuels Enhancing agricultural cycles & soil health 2️⃣ Direct Air Capture (#DAC) ☁️ Pulling CO2 directly from the atmosphere Converting it into feedstock chemicals & materials Storing it in long-term stable solutions 3️⃣ Industrial Carbon 🏭 Capturing emissions from key industrial processes Reusing it in manufacturing & supply chains Integrating circular carbon loops into production 🔑 Why This Matters: We’re not just removing carbon—we’re redefining its role by: ♻️ Creating sustainable feedstocks 🌎 Reducing fossil carbon dependency 🏗 Building resilient #supplychains ⚡ Driving industrial #decarbonization 💡 Key #Opportunities Ahead: 🚀 Materials Revolution: Carbon fiber, bio-based plastics, green construction 🛢 Chemical Transformation: Synthetic fuels, carbon-neutral commodities 🌱 Agricultural Integration: Soil carbon enhancement, sustainable fertilizers 🔥 The Future is Circular Carbon No more “extract-use-emit.” Instead, we need a circular model where: 🌿 Atmospheric CO2 becomes a resource 🔁 Products store carbon long-term ♻️ End-of-life carbon feeds new processes 🌍 Natural cycles are enhanced, not disrupted 🤔 What’s Next? 💭 How can we measure the transition to sustainable carbon sources? #MRV 🏗 What infrastructure do we need for circular carbon flows? 📈 Which industries and financial instruments will lead this transformation? Let’s turn carbon into an asset, not a liability. Who’s in? 👇 #CarbonEconomy #Sustainability #CircularEconomy #CleanTech #FutureOfIndustry #NetZero