AMAZING NEW MATERIALS AND THEIR FUTURE USES

COMPILED BY HOWIE BAUM AN INTRODUCTION TO THE DIFFERENT TYPES OF MATERIALS

• Materials used in the design and manufacture of products

• • Wood • Composites • Ceramics • • Fabrics

Linen,LayersTungstenBalsaSteel, cotton, ofAcrylic , wood carbidealuminium ,lens model tool Kevlar bit & acrylic

Classification of Materials (Metals)

•Metals can be further classified as Non- Ferrous (without iron) (shown first) and Ferrous (with iron)

HighStainlessAluminium CopperSpeedBrass Steel steel Ferrous Non-Ferrous

Steels Aluminium

Stainless Steels Copper

High Speed Steels Brass (Copper & Zinc)

Cast Irons

Stainless Steel Steel is alloyed with chromium (18%) and (8%) (which is why sometimes, it is called 18-8 .

It won’t rust because of the outer layer of Chromium oxide !

Hard and tough

Corrosion resistant

Comes in different grades

Sinks, cooking utensils, surgical instruments

The most popular form is Type 304 stainless

steel. 6 The 630-foot high, stainless-clad (type 304) Gateway Arch defines St. Louis's skyline. “CLOUD GATE” aka THE BEAN, IN CHICAGO It is made up of 168 stainless steel plates (Type 304) welded together and its highly polished exterior has no visible seams.

It measures 33 by 66 by 42 feet (10 by 20 by 13 meters) and weighs 110 tons !! The outside skin of the DeLorean car (Back to the Future model shown) was also made of Type 304 stainless steel !!

The operating flux capacitor from the DeLorean used in the movies “Back to the Future” !! NON-FERROUS METALS MOST ZIPPERS ARE MADE OF ALUMINUM !! OF ALUMINUM AND OTHER METALS

Extrusion is a manufacturing process where a material, often in the form of a billet, is heated to about 900 degrees F and then it’s pushed and/or drawn through a die to create long objects of a fixed cross-section.

What kind of foods are extruded? Chalk or Marker tray Extrusion has found a great application in Food Processing. Various products like pastas, breakfast cereals, hot dogs, ready to eat snacks, cookies like Fig Newtons, etc. are now manufactured by extrusion.

. Pasta Extrusion Methods GUMMI-BEARS

MACARONI LITHIUM CARBONATE FOR BIPOLAR DISORDER

LITHIUM BATTERIES, AND GREASE ZrOC

ZrOC is a new coating technique using the physical vapor deposition method (PVD) in which a mixture of zirconium, oxygen, and can be deposited on metal, , wood, glass, or textiles.

Depending on how those elements are mixed, you can get chrome in any color you choose. DISSOLVABLE, MAGNESIUM NERVE REGENERATION DEVICE

An implantable, biodegradable wireless device that speeds nerve regeneration and improves healing of a damaged nerve.

The device is the size of a dime and the thickness of a sheet of paper and dissolves in the body after about two weeks.

https://www.youtube.com/watch?time_continue=38&v=BoOlL5LPb7o 1 minute Magnesium metal or 3D printed porous shapes can be formed into patient specific scaffolds, for regeneration.

Over time, the bone grows into the scaffold and the Magnesium slowly dissolves away, which can eliminate the need for secondary removal surgeries.

Magnesium alloys (mixtures) such as 98% magnesium and 2% calcium, have better mechanical properties and corrosion resistance, than pure magnesium by itself. PLASTICS Classification of Materials (Plastics) •Plastics can be further classified as; • (melt when heated) •Thermoset (don’t melt) •Elastomers

Thermoplastics Thermosets Elastomers Acrylics Epoxy resins Rubbers Phenolic Silicones PhenolUrea formaldehyde formaldehyde Poly PVCPolyurethanesPolyethylene gutters

Rubber Polymeric Materials in Everyday Life

22

PLASTIC UNBREAKABLE BRICKS FROM RECYCLED PLASTIC

29-year-old Kenyan inventor Nzambi Matee is turning tons of plastic trash into super durable, lightweight bricks that cost a tenth of the price of normal bricks.

Plastic materials that can’t be normally recycled are shredded, mixed with sand, put through a high- temperature extrusion machine that makes it into a slurry, and then compressed into beautiful, colorful bricks.

https://www.youtube.com/watch?v=xUw2U8PB6EY 1.5 min REPLAST RECYCLED PLASTIC BLOCKS

A new startup called ByFusion created an eco-friendly way to repurpose collected ocean plastic permanently, in the form of construction blocks called RePlast. Classification of Materials (Wood) • Wood can be further categorized as; • Hardwood • Softwood • Manufactured board ChipboardCedarMahoganyBeechOakAshPlywood with Veneer

Hardwood Softwood Manufactured Board

Oak Pine Plywood Ash Cedar Blockboard Beech Fir Medium Density Fiberboard

Sycamore Spruce Melamine board 4D PRINTING OF PROGRAMMABLE WOOD MATERIAL

Novel printing and technologies can now overcome prior limitations of wood forming.

Flat sheets of custom printed wood composite can be designed to self- transform in controlled and unique ways. https://www.youtube.com/w atch?v=3pMPWdQf-Mk 1 minute REWALL CEILING TILES

They are made from recycled beverage containers–a mixture of cardboard, plastic bottles, and aluminum.

The result is a material that has the same structural integrity as wood strand board and can be cut and screwed into like wood.

It has much better resistance to moisture, so it can be used as a ceiling tile and exposed to the elements. WOOD SPONGE

It is made by using chemicals to remove hemicellulose and lignin, which leaves just a porous piece of cellulose.

It is a reusable, oil- wicking sponge made of wood that can absorb more than 40 times their weight in oil, to deal effectively with oil spills.

It has a waterproof coating on it so it https://www.youtube.com/watch? can just absorb oils and not water. v=3JqiSrMflN4&t=15s Go to 1.39 Classification of Materials (Composites)

• A composite is a combination of two or more chemically distinct materials (usually a fibrous material and a liquid resin) whose physical characteristics are superior to its constituents acting independently.

• Because of their high strength/stiffness to weight ratio they are widely used in the:

•Aerospace industry

•Offshore structures

•Boats

•Sporting goods Classification of Materials (Composites)

The 4 Types of composites include:

• Reinforced Plastics

• Ceramic-matrix

• Metal-Matrix

• Laminates

OuterCarbonCombustionKevlar, skinGlassThrust reinforced panels Cylinder taffetaCylinderreinforced chamberchamber & polyesterplasticfuselage liningslinings plasticoffor jet rocket A380sailsengine hull method by spraying chopped glass fibers and mixing them with resin to form a strong laminate. METAL MATRIX COMPOSITES

High temperature fibers dispersed in metal materials FIBER METAL LAMINATES

GLARE: “GLAss-REinforced” Fiber Metal Laminate (FML), composed of several very thin layers of metal (usually aluminum) interspersed with layers of glass-fiber “pre-impregnated with resin, bonded together with a matrix such as epoxy.

ARALL: Abbreviation for Aramid (Kevlar) aluminum laminate. Composite produced by adhesively bonding sheets of isotropic high- strength aluminum and tough aramid (Kevlar) fibers.

The aluminum provides higher strength isotropic properties and metal- forming qualities to the composite laminate while the aramid (Kevlar) fiber supplies fatigue and fracture resistance. USE OF GLARE CERAMIC COMPOSITES:

A brake disc (or rotor in U.S. English), usually made of cast iron or ceramic composites (including carbon, kevlar and silica), is connected to the wheel and/or the axle. Silicon Carbide Whisker-Reinforced Ceramic Composites FIBER MATERIALS USED FOR REINFORCEMENT IN PLASTIC COMPOSITES

(KEVLAR) CARBON FIBER PARTS !!

CARBON FIBER CELLO

FIXED WING AIRCRAFT WITH MORPHING FLAPS

FlexFoil™ adaptive control surfaces represent a major improvement over conventional aircraft flaps.

By exploiting the natural elasticity of aviation grade materials, the FlexFoil™ control surface changes the angle of a wing during flight, by using small electric motors to change the flap shape.

BIO-COMPOSITES • Bio-composites combine plant fibers with biodegradable resins to create natural based composite materials. BIODEGRADEABLE COMPOSITES

Nearly all of the current types of Composites can’t be recycled or reused.

The items shown are made with fibers from the Nettle plant which are very strong.

Nettle fiber is from the stem of 3 types of plants - European nettle, Ramie, and Himalayan nettle, which is similar to flax.

They can be mixed with (PLA) resin, made from corn starch, to form a composite that is biodegradable.

Classification of Materials (Ceramics)

• Ceramics are compounds of non-metallic elements, examples include;

•Oxides (alumina – insulation and abrasives, zirconia – dies for metal extrusion and abrasives, sandpaper

•Carbides (tungsten-carbide tools)

•Nitrides (cubic boron nitride, 2nd in hardness to diamond) Engine Products Kyocera engine products include cam rollers, turbocharger rotors, glow plugs, cylinder liners, seals, pistons, piston pins, valve and valve guides, fuel injection parts and various custom made components made from a wide selection of advanced ceramic materials.

Ceramic Piston Ceramic Seal Head and Assembly Rings

Ceramic Cam Ceramic Roller Turbocharger Rotor SILICON NITRIDE BALL AND OTHER TYPES OF BEARINGS CERAMIC COATINGS

TIN-NITRIDE CHROMIUM NITRIDE

TITANIUM ALUMINIDE CERAMIC KNIVES

KYOCERA KITCHEN KNIFE CONCRETE

It is one of the most frequently used building materials around the world.

Ton for ton, its use is twice that of steel, wood, plastics, and aluminum combined.

Globally, the ready-mix Novacem Carbon- concrete industry is projected Negative Cement to exceed $600 billion in revenue by 2025. Overall, the production process to The global production make 1 ton of Novacem cement process for standard absorbs up to 220 pounds more cement, produces 8% of CO2 than it emits, making it a greenhouse gas emissions. carbon negative product. NEW TYPES OF CONCRETE

SMART CONCRETE

The strength and condition of the concrete can be checked over time.

Short carbon fibers are added when it is made, to make it electrically conductive.

Its measured electrical resistance will change if there is strain or stress in it.

This finds possible problems before the failure of the concrete. https://youtu.be/X792nnogK8I 1 minute CARBICRETE

It is a low-cost building solution that help reduce greenhouse gases.

It is made with cement-free, carbon- negative concrete using mineral waste and then captures Carbon Dioxide (CO2) with the curing process.

▪ 30% stronger than standard concrete

▪ Annual CO2 emissions lowered by 20,000 tons

▪ 20% less cost than standard concrete FIBER REINFORCED CONCRETE

Enhances the durability and toughness of concrete.

Small fibers of glass, steel, plastic, or carbon are added to mixtures of concrete and mortar.

They increase energy absorption and fire resistance, while reducing shrinkage, crack, fracture formation, and crack size.

https://www.you tube.com/watch ?v=MuzChOwgCi o go to 1.28 FIBER REINFORCED CONCRETE CHAIR AND TABLE DESIGN RE>CRETE

Instead of using sand and gravel, RE>CRETE contains Portland cement mixed with shredded newspaper and junk mail, ground up packing Styrofoam, home electronics wire, credit cards and CDs, salvaged house paint, dryer lint,, and fly ash. CARBON FIBER- REINFORCED CONCRETE

A Carbon Concrete Composite has been made in Germany which aims to reduce concrete material use by 50% and CO2 emissions by up to 70%.

https://www.youtube.c om/watch?v=nB9ViglD Mmg stop at 2:06 TRANSLUCENT CONCRETE

Two configurations of WHAT IS fibers: TRANSLUCENT CONCRETE? 1)Organic •Translucent concrete is based on the concept of ‘Nano Optics,’ where 5% – 7% glass fibers act as slits to transmit light from one side of the surface to another. 2) Layered •These optical fibers are spread evenly through the concrete and are visible on both sides of the block.

Bacteria-Based, Self Healing Concrete

You need bacteria that can survive the harsh environment of concrete.

Bacillus bacteria will thrive in the high-alkaline conditions of concrete and produce spores that can live up to 4 years without any food or oxygen.

The concrete mix is finalized by adding calcium lactate to the limestone concrete mixture to feed the bacillus, so that they can produce limestone to repair cracks in the concrete. IMPROVED CERAMIC MATERIAL

Canon has developed a new proprietary ceramic material and 3D printing technology to create ceramic parts with complex geometries and little shrinkage.

The material is an aluminum oxide (alumina-based) material and is used with the (SLM) process for 3D printing. Classification of Materials (Fabrics)

•Fabrics can be further classified as natural and synthetic

Natural Synthetic

Cotton Nylon

Canvas Polyester

MaterialsCotton usedPolyester in T -ColourfulspaceshirtCanvasPolyester (design marinesuits decknylon include & kite ropechair printspinnaker- aluminizedlessprojects) Mylar, neoprene coated nylon,stretch dacron than, urethane nylon- resists coated UV nylon, light tricot and spandex. The outer layer is a blend of Gortex, Kevlar and Nomex Corn fiber

Made from corn starch, The Cargill Co. produces “”

Insect resistant

Performs like polyester

Breathable

Hypoallergenic

Superior softness

Biodegradable HEMP CLOTHING ITEMS BAMBOO FIBER AND FABRICS BioSteel is a trademark name for a high-strength fiber-based material made of spider web “silk” protein extracted from the milk of transgenic goats.

It is reportedly 7-10 times as strong as steel if compared for the same weight, and can stretch up to 20 times its unaltered size without losing its strength properties. Adidas unveils futurecraft biofabric – the world's first performance shoe made from biosteel® fiber The leading aerospace company Airbus and advanced biolpolymers producer AMSilk partner to develop the first composite material made of Biosteel® fiber. THE LATEST TECHNOLOGIES IN THE WORLD OF FASHION Smart textiles can be broken into two different categories: aesthetic and performance enhancing.

❖ Aesthetic examples include fabrics that light up and/or change color or shape

❖ Gather energy from the environment by harnessing vibrations, sound or heat, and reacting to these inputs.

❖ Embedding the fabric with electronics that can power it for light effects, changing shape, entertainment – games, smart phones, etc. Black Panther took home the 2019 Academy Award for Best Costume Design for outfits that included an intricate collar and crown created using 3D printing using the Selective Laser Sintering (SLS) process.

Among the elaborate costumes worn in the movie were a crown and huge shoulder mantle donned by Queen Ramonda, played by American actress Angela Bassett. 3-D PRINTED CHAINMAIL FABRIC MATERIALS THE KINEMATICS DRESS

The articulated 3D printed links in the previous picture were used to make this beautiful dress.

It is called the Kinematics dress and was designed by the Nervous System Company.

3D-scanning technology allows the design to be custom-fit to the wearer's body by manipulating the tessellated mesh file before printing.

Because of the openness in some areas, under garments are worn with it. https://www.youtube.com/w

DISCO DOG !

Classification of Materials (Smart Materials)

•A smart material can be described as a material that has a useful response (movement, etc.) to external influences or stimuli (force, light, etc.)

There are many examples of smart materials in everyday use that are not modern developments. They include; •Metal springs

•Light bulbs self regulate because as the filament temperature increases, their resistance rises

•Ancient civilizations have long used porous ceramics for self cooling

Wine Cooler SHAPE MEMORY METAL ALLOYS AND

The material "remembers" its original, cold, forged shape, and which returns to that shape after being deformed by applying heat.

The metal type (shown at right) is called Nitinol which is alloy of Nickel and Titanium. Shape memory alloys have applications in industries including medical as a stent which is inserted when it is cold and once in the blood stream, it expands automatically.

https://www.youtube.com/watch?v=QYp9rIJRM8s 1 min 3D-PRINTED BONE IMPLANT THAT DISSOLVES IN BODY

Scientists have developed a new type of 3D-printed polymeric and calcium phosphate bone implant.

It organically degrades as it is replaced by natural bone tissues.

It was made with a shape memory and was compressed twice in a protective, biodegradable covering, heated during the surgery and eventually become securely fixed into the renovated area of bone tissue. 4D printed soft gripper has shape memory hinges and adaptive tips and can be used to pick up screws.

It responds to heat, light, or electricity. FERROFLUIDS Ferrofluid is a liquid that is attracted to the poles of a magnet.

They are made of small magnetic particles, suspended in a soapy carrier fluid.

They can be used for seals on motors and cooling speaker coils. NEW TYPES OF FOAMS METAL AND CERAMIC FOAMS METAL FOAMS: • ALUMINUM • BRASS • TIN • ZINC • NICKEL • SILVER • GOLD • COPPER

CERAMIC FOAMS: • SILICON CARBIDE • CARBON • SILICON • SILICON NITRIDE/CARBIDE • BORON CARBIDE • BORON NITRIDE METAL USED IN CAR CRASH BOX TO ABSORB IMPACT

MANY CARS USE METAL FOAMS TO ABSORB FRONT END IMPACT

Crash absorber box of the electric car prototype developed in the European project 'Evolution'. It is made of rectangular aluminum alloy profiles filled with Al-foam. ALUMINUM HONEYCOMB PANELS

Top view shows the before and after impact for a Crash Box used on A formula SAE race car 3D PRINTED CERAMIC FOAMS FOAM Aerogel is a synthetic porous ultralight foam material usually made from Silica and is 99.9% air.

The result is a solid with extremely low density and is an excellent insulator from flame.

Silica feel like fragile expanded to the touch.

They are used as insulation in clothing for extreme conditions and other applications.

It is the world’s lightest metal and one of the lightest structural materials.

This synthetic porous material made from small nickel phosphorous tubes.

Potential uses include applications in automotive engineering, aeronautical engineering, and more. refers to materials, applications and processes designed to work on extremely tiny scales, usually for things between 1 and 100 nanometers long.

A nanometer is one-billionth of a meter. A sheet of paper is about 100,000 nanometers thick, while a single gold atom is about one-third of a nanometer in diameter.

88 Units in nanometers (µm) a billionth of a meter !

89 NANOPATCH – NO MORE SHOTS !!

It is the size of a postage stamp size and has thousands of tiny spikes on its surface which are only 60 to 100 millionths of a meter long - the width of a human hair.

Each spike is coated with a vaccine and then dried.

The spikes are just long enough to reach the living skin layer below, the epidermis and the dermis and only 1/10 to 1/30 of the dose is required, compared to using a needle and syringe. FOR ENERGY STORAGE

The high surface-to- volume ratio and excellent electrical conductivity of nanomaterials, make them excellent choices for high energy storage and power density.

They can be printed, used in sprayed coatings, for making wearable, flexible, and foldable energy storage devices. NANOPARTICLE SOLAR CELLS

A new nanomaterial pigment has been developed for use in solar cells, which acts like chlorophyll, that absorbs sunlight and generates electrons.

Each nanoparticle of titanium dioxide is coated with the pigment, and the result is a fluid that contains the nanoparticles with which solar cells are made. – HEXAGON-SHAPED PLANE OF CARBON ATOMS IN SHEET FORM Graphene, the basic structure for all graphitic materials, is a two- dimensional (2D) sheet of carbon atoms arranged in a honeycomb lattice structure.

The outstanding properties of graphene are:

❖Very high mechanical strength

❖High electrical and heat conductivity

❖Large surface area.

NANOTECHNOLOGY FORMS

Graphene is a flat sheet of carbon atoms arranged in hexagons.

Fullerenes are molecules of carbon in the shape of spheres, ellipses and tubes.

The sphere shape is known as buckminsterfullerene, or a buckyball

Carbon nanotubes, also known as buckytubes, are in the shape of a tube with the outside carbon atom structure made of Graphene. 5/11/2021 96 Porous, 3-D forms of graphene developed at MIT can be 10 times as strong as steel but much lighter

The new super-material is made up of flecks of graphene and the part is almost completely hollow.

Its superior properties are due to how the graphene planes are aligned.

https://www.youtube.com/watch?v=sVZjlvOYdLk go to 44 sec ECoG – Eastern Cooperative Oncology Group rating

ECG or EKG – Electrocardiogram (heart rhythm)

EMG – Electromyography (muscles & nerves)

EEG – Electroencephalogram (brain)

EOG – Electrooculography (eyes) FLEXIBLE BATTERY

ORIGAMI?

Scientists at Arizona State University have created a lithium- ion battery out of -coated paper.

Folding it like a map, they have increased the battery's energy density by 14 times

It makes it a perfect choice for tomorrow’s smart clothing, e-textiles, wearables, and flexible gadgets. NP – Nano-particle

5/11/2021 100 101 LAB-ON-SKIN Stretchable and flexible electronic devices as biosensors for measuring (clockwise from top right) skin modulus (stiffness)

Electro-cardiology

Hydration

Blood oxygen

Wound-healing rate

Sweat content

Skin surface temperature

Blood pressure Nanotechnology materials are going to open Electromyography new realms of possibility for flexible and stretchable monitoring gadgets that are Electroencephalography wearable directly on the skin WHAT IF OUR PACKAGED FOODS CAME IN EDIBLE WRAPPERS, JUST LIKE FRUITS AND VEGETABLES DO?

Wikicells are edible food packaging invented by a Harvard professor for making a very thin biodegradable shell surrounding a more robust edible shell, inside of which would sit the food or beverage.

The thin shell could be removed and composted, then the thicker shell could be eaten along with the food inside or composted as well – and just like that, plastic food packaging could become obsolete. 3D-PRINTED SUSHI

From the Japanese company Open Meals, which debuted its complex 3D-printed sushi in Austin, Texas last year. Plentiful and sometimes even edible, seaweed might just become the packaging of choice for food and beverage uses, cosmetics and other applications.

It’s cheap, easy to harvest and doesn’t require fresh water or Evoware seaweed-based packaging fertilizer to grow and can produced in Indonesia biodegrade in soil in less than six weeks.

Flexible red seaweed is used for disposable plates and cups and to make Agar for clear, jelly-like edible pouches. SEACELL FIBER

A new fabric called SeaCell, composed of seaweed and eucalyptus was created as a sustainable alternative to disposable diapers and the materials used in couture fashion. SEAWEED ROOF THATCHING

The centuries-old tradition of seaweed thatching was used to develop modern seaweed thatch panels for the building industry.

It was found that eelgrass is a fantastic material that is naturally fireproof, rot resistant, carbon negative, insulates well, and becomes waterproof entirely, after about a year.

. SHRILK

Some might even have a future in hospitals for tissue engineering, scaffolds, or suturing wounds.

A material called “Shrilk” comes from the wings and outer skeletons of arthropods like crustaceans, beetles and caterpillars

It’s translucent, resilient, pliable and strong. MYCELIUM

Mycelium is the underground portion of fungi we see growing out of the soil, and it can be used to produce a surprisingly strong material that can be grown into molds of virtually any size and shape.

It is made with several species of fungi along with farming byproducts like leaves, mulch, seed hulls from rice and cotton gin waste to create a sort of styrofoam alternative that’s actually more Ultra-Violet stable than foam and just as water-resistant.

The material breaks down within MYCELIUM PACKAGING BY 180 days, whether in a landfill or EVOCATIVE DESIGN somebody’s backyard. CRUNCHY FOOD NEST SERIES

These Food Nests use the tomato as the main ingredient and explore the hand- size container as well as the larger group- size container for sharing. DRONE CHASSIS DESIGN USING GENERATIVE DESIGN AND MACHINE LEARNING

https://www.youtube.com/watch?v=odHC-gxJhG4 1 min.111 USING GENERATIVE DESIGN AND 3D PRINTING FOR AN ARM CAST

3D printing and using Generative design, allowed for better minimalism, materiality, and customization.

With a generative cast's slim profile, it looks better than a plaster cast.

The material - 3D-printed ABS (Acrylonitrile Butadiene Styrene) plastic allows patients to wet their casts while taking a shower, and the open features also allow for ventilation of the affected area that can speed up the healing process. The Voxel Chair is 3D printed using a different method than on a flat surface that moves.

It is made from transparent, biodegradable Polylactic Acid (PLA) plastic which is made from corn, with a blue tint,

BIBLIOGRAPHY https://interestingengineering.com/7-new-materials-invented-in- 2018-that-could-change-our-lives https://www.letsbuild.com/blog/10-innovative-construction- materials https://www.dezeen.com/2019/12/29/innovative-materials- 2019/ https://www.fastcompany.com/3065607/11-exciting-new- materials-designers-should-watch https://www.sciencedirect.com/science/article/abs/pii/S02641275 17302034 https://www.uni- muenster.de/MEET/en/research/materials/alternativeenergymater ials.html