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Low Carbon 3D Printed Homes – Lower Cost too

Posted on November 23, 2023 by dishanth

An emerging application of 3D printing technology is fabricating entire homes through additive manufacturing. Early adopters demonstrate that 3D printing residential buildings carry significantly lower embedded carbon than conventional construction methods.

By optimizing materials and printing processes, 3D home printing could provide affordable, efficient, low-carbon housing to growing populations if adopted at scale.

Also known as additive manufacturing, 3D printing builds structures by depositing materials layer by layer according to digital models. Concrete is typically extruded through a moving print nozzle onto a substrate, hardening upon deposition to gradually form walls and roofs of low carbon 3D printed homes.

Companies pioneering low carbon 3D printed homes include Icon, SQ4D, and Mighty Buildings. Their printed concrete or polymer designs streamline manual labor of framing, insulation, and finishing. Architectural designs are also easier to customize versus cookie-cutter manufactured units.

But the sustainability benefits are among the most significant advantages over current construction. Architect Sam Ruben, an early adopter of 3D printing for eco-homes, states that 3D printing can reduce lifecycle emissions by over 50% compared to standard building techniques.

Part of the savings comes from more efficient material usage. Conventional construction methods are wasteful, generating excessive scrap materials that go to landfills—3D printing deposits only the needed amount layer-by-layer, eliminating waste.

Printing also allows easier integration of recycled components like crushed concrete aggregate into prints, diverting waste streams. And lightweight printed structures require less embedded energy to transport modules. Optimized print geometries better retain heat as well.

But the biggest factor is speed – printed homes can be move-in ready in days rather than weeks or months. A standard SQ4D home prints in just 8-12 hours of machine time. Accelerated production means less energy consumed over the total construction period.

And speed has financial benefits, too, reducing the logistical costs of prolonged projects. Combined with simplified labor, 3D printing can cut estimated construction expenses up to 30%. Those cost savings make printed homes more accessible to low-income groups while stimulating large-scale adoption.

To quantify benefits, Mighty Buildings completed a life cycle assessment comparing their printed composite polymer dwellings against conventional homes. They estimated their product cut emissions by over one-third during materials and construction. Waste production dropped by over 80%.

Such data helped the company achieve third-party verified EPD declarations certifying their low carbon 3D printed homes. Mighty Buildings believes printed homes could eliminate over 440 million tons of carbon emissions if comprising 40% of California’s housing needs by 2030.

Despite advantages, barriers remain to limit widespread 3D printed housing. Printed buildings still require finishing like plumbing, electrical, windows, and roofing. Developing integrated printing around and including those elements will maximize benefits.

High upfront printer costs also impede adoption, though expected to fall with scaling. And building codes need updates to cover novel printed structures despite proven duribility. Some jurisdictions like California are pioneering efforts to add low carbon 3D printed homes as approved models in housing codes.

But if technical and regulatory hurdles are resolved, additive construction could offer meaningful emissions cuts. With global populations projected to add 2 billion new urban dwellers by 2050, low carbon 3D printed homes may become a go-to sustainable building technique, especially in growing developing countries.

The urgent need for dense, low-carbon housing solutions to accommodate global populations makes 3D printing’s advantages stand out. Printed homes advance from gimmick to viable strategy against climate change.

Eco-conscious homebuyers on a budget have a new choice – low carbon 3D printed homes made from low-carbon cement. A new housing tract in Round Top, Texas has introduced small dwellings printed using concrete that produces just 8% of the carbon emissions of traditional Portland cement manufacturing.

Habitat for Humanity last year unveiled its first low carbon 3D printed home in Williamsburg, Virginia. The project represented Habitat for Humanity’s first completed 3D printed home in the country.

By combining 3D printing techniques with more sustainable cement mixtures, homebuilders can reduce the carbon footprints of affordable printed housing even further.

Source Happy Eco News

Creating Fabric Materials out of Bacteria

Posted on April 24, 2023April 24, 2023 by dishanth

Fast fashion is a sector of the fashion industry whereby business models rely on cheap, rapid and large-scale production of low-quality clothing. Today’s clothing is made of durable and cheap materials such as nylon or polyester. Approximately 60% of fast fashion items are produced with plastic-based fabrics. The microplastics in these garments leach into the waterways with each wash and dry. Half a million tons of these contaminants enter the ocean each year. The fashion industry is also the world’s second-largest water supply consumer. On top of it all, more than 85% of the textiles and clothing purchased will end up in landfill every year.

Modern Synthesis, a biotechnology company, has created a biomaterial made from bacterial fermentation that can be used to create a low-carbon alternative to traditional clothing fabrics. The material the bacteria produces is called nanocellulose, which the company takes from waste feedstocks, including fruit or other agricultural waste. The bacteria will grow on that sugar and naturally produce nanocellulose.

The nanocellulose fibers are very strong and so small that they create strong bonds when they stick to each other. The fibers are eight times stronger than steel and stiffer than Kevlar. With the nanocellulose, the company is creating a material similar to nylon, ripstop fabric (woven fabric made out of nylon) or a coated textile. The material is designed to feel dry and warm, resembling cellulose or paper.

The process of creating the fabric can be adjusted by using different types of thread, some of which can biodegrade, while other threads can be recycled similarly to other cellulose. The project started with the creation of a shoe. Still, thanks to the material’s versatility, the company thinks it can be a good alternative to traditional textiles as it can also be dyed and given different coatings.

They believe their nanocellulose fibers are a significantly more sustainable fabric alternative to cotton, which takes a lot of resources and energy to transform. This material creates significantly fewer emissions than traditional textiles as it only requires transforming waste sugar into usable material. While the material is not yet available for consumer use, the company offers research, development, and consultation services to help brands make better, more environmentally friendly material choices.

As the fashion industry looks for more sustainable ways to make garments, many companies are moving towards using biomaterials to create new textiles. We are now seeing leathers made from fruits and vegetables, sequins made from algae, and so much more. As fast fashion continues to be a problem, the efforts that companies like Modern Synthesis are taking will help the industry reduce its environmental impact while continuing to clothe the world.

Source Happy Eco News

Decarbonizing Aluminum; a Low-Carbon Future for a Versatile Metal

Posted on March 28, 2023March 28, 2023 by dishanth

What is aluminum, and what is it used for?

Aluminum is a silvery-white, soft, nonmagnetic metal. It has good electrical and thermal conductivity and is used in many products, from cars and airplanes to packaging, foil and cans. It is a highly versatile metal, but many people don’t realize that it’s also one of the most carbon-intensive metals to produce.

Because it is used in so many diverse applications, the aluminum industry has a big environmental footprint. Aluminum production emits about 1% of global man-made greenhouse gas emissions. Most of these emissions come from using fossil fuels to make aluminum oxide (alumina), which is then reduced to aluminum metal in smelters.

The aluminum industry is working on ways to reduce its emissions. One promising technology is “carbon-free” or “green” aluminum production. This process uses renewable electricity – instead of fossil fuels – to produce alumina, which can then be turned into aluminum metal using existing smelting technology.

Several companies are already using or testing this technology, including Rio Tinto, Alcoa, Hydro and China’s Chalco. These companies are betting that carbon-free aluminum will be in high demand from industries and consumers who want to reduce their emissions footprints.

Why is aluminum production carbon-intensive?

There are two main reasons why aluminum production is so carbon-intensive. First, alumina, the raw material used to produce aluminum, is derived from bauxite ore, typically found in tropical regions. The process of mining and refining bauxite ore releases large amounts of carbon dioxide into the atmosphere.

Second, smelting alumina to produce aluminum metal emits significant amounts of carbon dioxide. Smelting is responsible for approximately two-thirds of the total emissions associated with aluminum production.

How will the industry decarbonize aluminum?

The most common method of producing aluminum involves the electrolysis of alumina in a high-carbon anode, which results in significant emissions of greenhouse gases. The industry is developing low-carbon technologies to reduce or eliminate these emissions.

Another promising technology is using renewable energy to power the electrolysis process. This would significantly reduce the carbon footprint of aluminum production. Solar, wind, and hydroelectric power can all power these processes while significantly reducing or eliminating emissions.

Recycled aluminum requires less energy to process and emits far less carbon dioxide than virgin alumina.

Each of these options comes with its challenges, but the aluminum industry is committed to finding ways to reduce its environmental impact. For example, Rio Tinto is investing in research into new smelting technologies that could significantly reduce emissions. Alcoa is working on a project to power its operations with renewable energy from forest biomass waste.

Will the quality of low-carbon aluminum be lower?

Decarbonized aluminum is made using low-carbon methods, which results in a lower carbon footprint. However, some worry that this type of aluminum will be of lower quality than regular aluminum.

No evidence suggests that decarbonized aluminum is any less strong or durable than regular aluminum. In fact, it may even be of higher quality due to the extra attention to the manufacturing process and modern innovations in the process. Low-carbon methods often result in a cleaner and more pure product.

A study by the International Aluminum Institute found that, when using best practices, there was no significant difference in the quality of low-carbon aluminum and regular aluminum. The study found that, in some cases, low-carbon aluminum had superior properties.

This is because environmental regulations are becoming more stringent, forcing producers to innovate and find ways to reduce their carbon footprint without compromising on quality.

Source Happy Eco News