Decorative Architectural Panels from Agricultural Byproducts

Proposed study is in response to the USDA NIFA SBIR Phase I Topic Area 8.8 "Biofuels andBiobased Products." Formology specializes in the innovation manufacture commercialization andsale of specialty wood and natural fiber panels for architecture and design/build markets; and wouldlike to meet the demands of the architecture and design (A&D) industries for environmentallysustainable and responsible product options. Building on the preliminary work by our collaboratorsat Washington State University on resin transfer molding (RTM) of agricluture residues wepropose to conduct further research to scale-up the manufacturing process to produce thick 4 ft by 8ft panels with mechanical performance dimensional stability and high-quality surface finishrequired for decorative architectural panels. Four tasks to achieve this objective are to: design andfabricate a large-size aluminum mold determine a protocol to consisently build a binder-lesshazelnut shell preform within the mold cavity evaluate and establish ideal resin infusionparameters and manufacture large-size panels and evaluate their performance.Proposed solution will produce strong stiff dimensionally stable and aesthecially pleasing panelsusing agricultural byproducts and provide Formology new business opportunities. Additionallyutilization of agricultural waste streams such as hazelnut shells to produce higher value productswill not only have environmental benefits of reduced burden on landfills and carbon storage butwill also lead to new opportunities for tree nut growers and processors. We anticipate the RTMpanels to be at a medium price range so we can offer performance and aesthetic advantages whilebeating out many higher priced materials.