SBIR-STTR Award

Proposed study is in response to the USDA NIFA SBIR Phase I Topic Area 8.8 "Biofuels and Biobased Products." Formology specializes in the innovation manufacture commercialization and sale of specialty wood and natural fiber panels for architecture and design/build markets; and would like to meet the demands of the architecture and design (A&D) industries for environmentally sustainable and responsible product options. Building on the preliminary work by our collaborators at Washington State University on resin transfer molding (RTM) of agriculture residues we propose 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 finish required for decorative architectural panels. Four tasks to achieve this objective are to: design and fabricate a large-size aluminum mold determine a protocol to consistently build a binder-less hazelnut shell preform within the mold cavity evaluate and establish ideal resin infusion parameters and manufacture large-size panels and evaluate their performance. Proposed solution will produce strong stiff dimensionally stable and aesthetically pleasing panels using agricultural byproducts and provide Formology new business opportunities. Additionally utilization of agricultural waste streams such as hazelnut shells to produce higher value products will not only have environmental benefits of reduced burden on landfills and carbon storage but will also lead to new opportunities for tree nut growers and processors. We anticipate the RTM panels to be at a medium price range so we can offer performance and aesthetic advantages while beating out many higher priced materials.

The Architecture and Design (A&D) industry is constantly in need of new, attractive, durable, and sustainable materials to specify for use in their design projects. Our research through Phase II will continue the success of Phase I in bringing to market a line of beautiful, unique, strong and highly sustainable panels made from agricultural and other byproducts which can be specified in many applications including wall and ceiling panels, cabinets, furniture, tabletops, flooring and more. By introducing these innovative products to the A&D industry we are effectively making it possible for everyone to have access to highly sustainable and quality panels for use in their interior/exterior construction and design projects. Whether it is a home owner using our panels for their kitchen countertops, a large corporation needing desks or a hospital needing a solution for attractive and highly durable wall coverings, our materials will provide excellent solutions. The introduction and large scale sales of our panels will also provide excellent opportunity to the agricultural community to up cycle their waste and increase their "bottom line". By selling their byproducts to Formology rather than paying for them to be discarded in landfills, farmers/growers will not only contribute to a new and sustainable product, they will also turn a cost into a revenue stream. It is not only the argiculture industry who will benefit from these opportunites. Manufacturers of other products who end up with waste materials such as textile scraps, coffee bags, wood waste, glass, plastics and more will have the chance to sell these byproducts to Formology rather than sending them to the landfill. There will be multiple steps taken to produce data/results in both tecnical/machanical areas and marketing/commercialization. First, we will build on the successful research of Phase 1 and continue with tests to determine the best methods for panel production. These steps will include refining/optimization of the metal mold for efficient infusion of resin, experimenting with different methods to maximize packing of fiber content, determining the best methods and equipment for removal from the mold and manipulation of the finished panels and others. We will also conduct technical testing to learn and optimize structural properties such as surface hardness, bending/breaking strength, screw withdrawal, moisture resistance, reaction to heat/cold, etc. Once we have this critical data we will have the tools to educate and inspire the A&D community as to the quality and benefits of using our materials. This education will come in the form of email outreach to our extensive network of designers, trade show appearances, ongoing individual and group presentations both in person and through Zoom, creating photo/video marketing assets for both physical pamphlets and website presence, etc. Once manufacturing techniques and market outreach have been executed and refined we expect to achieve a strong market presence with our new and innovative agricultural panels. Our goal is to continue on the success of our existing wood based panels and our strong relationships within the design community to propel our new materials to high sales volume rapidly. By carving out a good portion of overall industry panel sales we will be ensuring that more projects contain our materials which have highly sustainable properties rather than the high resin, laminate, plastic and other non-sustainable products. At the same time we will offer opportunities for members of the agriculture and other industries to reduce waste and create more revenue for the businesses. Our new manufaturing facility will create and sustain jobs not only within our company but in those that supply us with raw materials, machinery and custom fabrication.