Biocomposites

The bio-composites we have been developing with Pond are 100% non-toxic, plant based, recyclable and have thermal and mechanical propperties that mean they can be a replacement for conventional composites.

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Inspired by Arundel Forest Garden and the way nature creates matter, I set out to find the most ecological materials that I could to build the Green Camp System That I designed (pannelised modular habitat). After attending the JEC Composites conference in France and speaking to just about every exhibitor there I discovered some amazing biomaterials and started to test these materials to see if they would be suitable for making our Green Camp System from, exploring various manufacture approaches including vacuum bagging with recycable bags and wooden tools, heated presses with second hand MDF presses and metal tools and finally additive manufacturing which was the final method chosen.

The three main materials that we tested and are still working with are:

1. Sicomin's GreenPoxy...

www.sicomin.com

is a 80% biobased thermosetting Expoxy system. We tested the product neat making incredibly strong transparent panels and with both natural and glass fiber panels. Boats and transparent visors for aircraft are made with this resin so it's well understood but the boat builders we performed the tests with could not believe the couldn't smash the pure resin test panels we made even when Dave was driving the biggest hammer they had at the test panel.

Our first 100% resin Sicomen test panels

2. Pond 100% non-toxic biocomposites...

www.pond.global

were developed by Martin Jensen, the CTO behind the resin systems for Seimens Windpower. They could not publish the extensive material testing that they had conducted with IKEA, Niike, NASA and others but assured me that the material propperties were just as good as conventional resin systems. Again, none of the community I was working with in the composite industry would believe we had a 1 for 1 replacement for the toxic composite resins that was 100% non-toxic so I engaged with tests with The National Composite Centre, the UK national lan to create test panels and perform basic mechanical testing including testing stregth at different temperatures (Temperature Deglassing). The full data can be provided on request but some of the pages from these tests are in the gallery below.

TG tests

3. UPM Formi...

www.upmformi.com

When we realised that manufacturing the biocomposite panels for The Green Camp System with heated presses would be expensive to set up, with each tool costing about £10k even if we just needed to make small changes to the design, I decided to focus on Additive manufacturing. Martin at Pond had not testied his bio-composite pellets out with AM so we started working with UPM Formi, The World's largest paper company that have developed a 99% biobased material for additive manufacture. We started tests with their material and many of the world's leading large format 3D printing companies. Eventually I designed The Big Green Machine as the only thing that I could afford to access was a machine I would build myself: off the shelf products were costsing anywere upwards of £50k - botching together refurbished robots would cost about £20k and need a dedicated industrual space; I only had my garage and wanted this technology as accessable as possible so I pushed ahead with UPM Formi's donated materials and am still building with them experimenting with Ponds 100% biocomposites in blends too.

Pond & UPM pellets we had made with sized Flax in the pond and wood cellulose in the UPM pellets (the lighter coloured pellets).

To view a long album with all the pics and short vids of the testing of these materials see here

GREEN TEAM

Martin Jensen

Chief Technology Officer

Martin and his team used to work at Siemens Wind power designing and building the world's largest wind turbines from composites. He broke away to develop the 100% non-toxic bio-composites we are using in our Green Camp System.
PROFILE PAGE

Tony Chignel

Bio-composite development

Tony assisted Green Campus in first winning the deal with Martin to start running tests with his bio-resin.
PROFILE PAGE

Simon Rogers

Rogers Advanced Composites

Simon is an expert naval engineer, specifically in the world of composites and he has been very supportive of the development our bio-composites and manufacture.
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Sean Singleton

Build Partner

Sean and his team have been supporting with the construction of prototypes, introduction of the bio-materials and 3D printing technology to the marine and composites industry. We are working to set up manufacture together at their HQ at Northshore Boatyard in Itchenor Harbour.
PROFILE PAGE

Sinesh Shah

Chief Financial Officer

A strong leader with Board Director and Investment Committee experience of resolving commercial issues and approving investment decisions.
PROFILE PAGE

Charles Fraser

Founder and general secretary

Charles is the founder, lead designer and CEO of Green Campus working on systems that provide for all of our needs in a regenerative way.
PROFILE PAGE

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Pond Biocomposite Resin for Natural Fibres (1m felt roll)

Resin comes in felt rolls. Lay up this 100% non-toxic biocomposite resin in sheets between the layers of fibre re-enforcement (FLax, Jute, Hemp etc). Recommend 50-50 fibre to resin. Sold in rolls of 10metres minimum. 10% discount for 100 meters and so on. 100% non-toxic, 100% plant based, Tg of 140C, Strength 108MPA (with natural fibre), Stiffness 40GPa (Young's modulus)

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JOURNAL

The Green Campus Journal chronicles the latest journal entries from all green team members. Look out for the monthly Green News Show for an in-depth update about what's been going on!

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Provide for your needs and comforts in ways that are of benefit to you and every other being: or at least do their best to cause as little harm as possible.

Pond Biocomposite Resin for Natural Fibres (1m felt roll)

Resin comes in felt rolls. Lay up this 100% non-toxic biocomposite resin in sheets between the layers of fibre re-enforcement (FLax, Jute, Hemp etc). Recommend 50-50 fibre to resin. Sold in rolls of 10metres minimum. 10% discount for 100 meters and so on. 100% non-toxic, 100% plant based, Tg of 140C, Strength 108MPA (with natural fibre), Stiffness 40GPa (Young's modulus)

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UPM Formi Biocomposite Pellets for 3D printing

99% bio-based biocomposite for 3D printing. A PLA like product with wood celulose fibre re-enforcement. UPM Formi biocomposite has high performance qualities with lower carbon footprint than fossil-based materials. The biocomposite combines mouldability of plastics and strength and sustainability of wood. Compared with traditional oil-based plastic, it reduces the product’s carbon emission by -50 %. It is a cost- and resource-efficient alternative for reducing the environmental impact of products.

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