Decorative Architectural Panels from Agricultural Byproducts

PROJECT SUMMARYProject SummaryProposed study is in response to the USDA NIFA SBIR Phase II Topic Area 8.8 "Biofuels andBiobased Products." Formology specializes in the innovation manufacture commercializationand sale of specialty wood and natural fiber panels for architecture and design/build markets; andwould like to meet the demands of the architecture and design (A&D) industries forenvironmentally sustainable and responsible product options. Building on the Phase I work byour collaborators at Washington State University (WSU) on resin transfer molding (RTM) ofagricultural residues we propose to conduct further research to optimize the manufacturingprocesses of producing 4 ft by 8 ft panels with mechanical performance dimensional stabilityand high-quality surface finish required for decorative architectural panels.A significantachievement in Phase I project was design and fabrication of an all-metal mold for RTMcommercial-size natural fiber panels. We further propose to identify produce and optimize 4 ftby 8 ft panels using the same machinery and processes with other agricultural byproducts i.e.sunflower seed hulls ancient grain hulls flax hemp hurd and even textiles made from cottonsuch as denim or recycled coffee bags.Five tasks to achieve these objectives are to: determine aprotocol to consistently build binder-less preforms within the mold cavity of various agriculturalbyproducts identify through trials the most ideal resin type infusion parameters and maximizefiber volume fraction for efficient and effective resin transfer make large-scale prototype panelsfor performance evaluation learn from continuous production and panel properties the aspectsand possible design modifications of the mold and fabricate a new all-metal mold whileincorporating the modifications for installation at Formology and subsequently train ouremployees.Proposed solution will produce strong stiff dimensionally stable and aesthetically pleasingpanels using agricultural byproducts and provide Formology new business opportunities.Additionally utilization of agricultural waste streams such as tree nut shells and grain hulls toproduce higher value products will not only have environmental benefits of reduced burden onlandfills and carbon storage but will also lead to new opportunities for growers and processors oftree nuts and other agricultural residues. We anticipate the RTM panels to be at a medium pricerange so we can offer performance and aesthetic advantages while beating many higher pricedmaterials.Other resin-based panels available to the A&D market are often made from up to100% resin while our RTM panels have already been produced with close to or above 50%agriculturally based fibers. These high fiber volume fractions result in very different aestheticproperties with our hazelnut shell and other agricultural fiber rich panels giving us an excellentcompetitive advantage.The A&D industry is constantly in need of new attractive durable and sustainable materials tospecify for use in their design projects.Currently they have very limited panel options in thisregard.There are very few materials made from agricultural byproducts in general and almostnone with a high percentage of this byproduct while offering excellent structural performancemoisture resistance dimensional stability and aesthetic value.Our research through Phase IIwill continue the success of Phase I in bringing to market a line of beautiful unique strong andhighly sustainable panels which can be specified in many applications including wall and ceilingpanels cabinets furniture tabletops flooring and more.1 | P a g e