Hi, MCC 97!

Material Exploration and Product Concept

Development

New Materials and Means of Production

MUO-E3000

Lecturer Teppo Vienamo

Doctoral Candidate Oldouz Moslemian
THE TEAM

Maruša Dolinar
MA Collaborative and Industrial Design
marusa.dolinar@aalto.fi

Lingfang Shen
MA Interior Architecture
lingfang.shen@aalto.fi

Jui-Fan Yang
MA Collaborative and Industrial Design
jui-fan.yang@aalto.fi
ABSTRACT
The objective of this project was to experiment with microcrystalline cellulose-
based materials in order to develop concepts and prototypes for potential product
applications which should utilize the properties of the developed material in a
sustainable and creative way.
By experimenting with the initial 6 variations of microcrystalline cellulose, we
developed 97 different MCC-based materials, from which a hard MCC-based foam
has the most potential. The latter represents a completely biodegradable and
sustainable alternative to many synthetic materials and could potentially be used in
acoustic panels design, protective packaging and as a core material in composite
wooden furniture.
Apart from initial desktop research, the emphasis was on “hands-on”
experimentation that was conducted through rapid prototyping in the CHEM-ARTS
laboratory. This enabled us to gain a deeper understanding of the material and
recognise viable product concepts faster.
CONTENTS
1. INTRODUCTION OF THE MATERIAL DEVELOPMENT PROCESS.............................................7
METHODOLOGY........................................................................................................................................... 10
INITIAL SAMPLE CATEGORIZATION........................................................................................................ 11
2. CELLULOSE-BASED MATERIAL DEVELOPMENT.........................................................................12
EXPERIMENTATION PHASE 1....................................................................................................................13
EXPERIMENTATION PHASE 2.................................................................................................................. 16
EXPERIMENTATION PHASE 3.................................................................................................................. 18
EXPERIMENTATION PHASE 4...................................................................................................................21
EXPERIMENTATION PHASE 5..................................................................................................................24
EXPERIMENTATION PHASE 6..................................................................................................................28
EXPERIMENTATION PHASE 7...................................................................................................................31
EXPERIMENTATION PHASE 8..................................................................................................................34
EXPERIMENTATION PHASE 9................................................................................................................. 40
EXPERIMENTATION PHASE 10................................................................................................................44
EXPERIMENTATION PHASE 11.................................................................................................................45
EXPERIMENTATION PHASE 12.................................................................................................................47
EXPERIMENTATION PHASE 13.................................................................................................................49
EXPERIMENTATION PHASE 14.................................................................................................................52
EXPERIMENTATION PHASE 15................................................................................................................ 58
3. POTENTIAL APPLICATIONS..............................................................................................................67
ACOUSTIC PANELS.................................................................................................................................... 69
PROTECTIVE PACKAGING......................................................................................................................... 74
REDESIGNED MATERIAL FOR FURNITURE......................................................................................... 80
SCENTED PLATE FOR INTERIOR............................................................................................................82
OTHER APPLICATIONS...............................................................................................................................84
4. OVERVIEW............................................................................................................................................85
REFERENCES.............................................................................................................................................. 88
TASK OUTLINE

This report has been written as a part of the MA Collaborative and Industrial Design
study program during the New Materials and Means of Production 2019 course
led by lecturer Teppo Vienamo and doctoral candidate Oldouz Moslemian at Aalto
University.

The aim of the task was to develop concepts and prototypes for potential product

1
applications from 6 variations of cellulose-based materials, which were presented
to students during a lecture by Professor Olli Dahl.

INTRODUCTION
All 6 variations of the cellulose-based material, provided by the School of Chemical
Engineering, are based on microcrystalline cellulose (hereinafter referred to
as MCC). MCC is a refined wood pulp, which can now be produced with a more
affordable price and fewer chemicals due to the new AaltoCell-technology, recently
developed by Aalto University. Currently, the knowledge about this material’s
performance in different manufacturing processes, the characteristics of the
OF THE MATERIAL
processed material, and its application area is still limited. Therefore, the task was
to conduct “a quick and dirty” experimentation with all the samples of different DEVELOPMENT
PROCESS
variations of the material to gain a better understanding of MCC. The material tests
served as inspiration towards a systematic idea generation of possible application
areas for the material, which were finally developed into the product concepts.

7
1. Introduction of the Material Development Process

Microcrystalline cellulose (MCC) is a refined, purified wood pulp, which is used as Our initial notions stated in the counter brief were the following:
an additive in paper and board, a bulking agent in livestock feed and extender
in pharmaceutical tablets (Finnish Forest Association, 2017). It is partially • How could transparency be achieved with MCC?
depolymerized cellulose prepared by treating alpha-cellulose, obtained as a pulp • MCC is flammable – could this property be perceived as a benefit? Is it feasible
from fibrous plant material, with mineral acids (Fao.org, 1996). to develop a candle from MCC that could be scented in order to form the
mystic interior ambient?
Since this was the first time, we have interacted with MCC, we initially examined • Could MCC be used in colour pencils?
MCC and its properties through literature and practice. Afterwards, we theoretically • Could the appearance of other materials be replicated with MCC composites?
familiarized ourselves with the material’s properties such as acoustic properties • Could the MCC be used instead of plaster and if so, what are the benefits?
(acoustical absorption), mechanical properties (brittleness, durability, elasticity, • Could hard, durable and strong hollow tubes be produced from MCC for
flexibility, etc.) and optical properties (transparency, colour), since we assessed that application in furniture or construction industry?
such understanding would help us with material experimentation and discovery of • Could MCC be used to produce pots for soil-less cultivation of plants?
potential applications.
Due to the short time frame of the course, we were not able to fully explore all of
At this point, we were mostly interested in the material’s benefits in comparison to the above stated ideas, but managed to shortly examine some of them.
other versions of cellulose, such as nanocrystal cellulose (hereinafter referred to
as NFC) and ordinary cellulose fibers, since the goal was to propose improvements The following sections, divided in experimentation phases, describe our material
in current applications of cellulose-based materials or even come up with new development process in detail. Results of each experimentation phase are shown in
possible utilization. Eventually, we became aware of the fact, that our lack of the tables and further elaborated in the results sections.
chemical knowledge could be overcome more easily through practice instead
of theory, since the scientific articles we have read, had almost no effect on
our capability of predicting the outcomes of the experiments we were about to
conduct. We ambitiously planned experiments that envisioned combining MCC with
other materials such as clay, glass, wax, concrete, various plastic materials and
testing of the composites’ properties, but were, due to the short time frame of
the course, forced to focus on conducting only more feasible ones. Our goal was
to identify crucial advantages and disadvantages of the composites, so we could
further conceptualise the potential benefits of the material’s downsides as well as
upsides.

8 9
1. Introduction of the Material Development Process

METHODOLOGY INITIAL SAMPLE CATEGORIZATION

Most of the practical material experimentation was conducted in the CHEM-ARTS Since that was the first time, we were to the CHEM-ARTS laboratory, the initial
laboratory, however, since we were dealing with non-hazardous cellulose-based introduction of the machines, rules and facilities in the laboratory was carried
materials, some experiments were also done at home. The entire process and out by the laboratory personnel. Afterwards, 6 different samples of MCC were
experimentation were precisely documented after each experimentation phase. presented, which were further classified and marked with Arabic numerals by our
group. The intention of that was to ease documentation of further experiments
In order to assure reproducibility of the experiments, the amounts of the used throughout the entire project and simplify the communication among students. Our
substances were weighed when conducting each experiment throughout the entire notation of samples with Arabic numerals is shown in Table 1.
project. All units are stated in grams. Each resulting test sample of a specific
experiment was marked with a letter S (indicating the word sample) and reference
number marking the experiment; for example, the outcome of the seventh Table 1
experiment is referred to as S7. When describing the experimental procedure,
remarks such as MS7 - mixture resulting in S7 - are made, which denotes that an Sample Sample Sample properties
undried mixture of test sample S7 was used. name
1 Dry MCC White powder, very dry
Before drying, the mixtures of samples were usually formed into planar patches 2 Dry matter 40% Small white particles
with different thicknesses – thick and thin patches to compare the results. If there 3 Birch MCC Bigger white particles
was no fundamental difference between thin and thick sample produced from the 4 Unbleached gel White gel
same mixture, both samples were described under the same name in the tables. 5 Bleached gel Light brown gel, a little smelly
6 Masuko grinded MCC, 90 % White liquid with consistency
The drying was either executed freely at room temperature in the laboratory or in water, 10 % MCC similar to yoghurt
a preheated oven overnight. In cases where drying conditions differ, that is clearly
stated. The outcomes that caught our further attention and were recognized as
the material composites with high potential for further exploration are marked with
colour throughout the entire experimentation part of the project.

1 2 3 4 5 6

10 11
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 1

Our experimentation started by mixing original samples together, since we wanted

to explore the properties of resulting composite materials.

Before drying, the mixtures of samples were formed into planar patches with
different thicknesses – thick and thin patches to compare the results. The drying
was executed freely at room temperature in the laboratory. The results of each
experiment of first experimentation phase are shown in Table 2.

2
Table 2

CELLULOSE- Test
samples
Samples mixtures Outcomes

S1 1 (2g) + 2 (2g) + Fragile, powdery

BASED MATERIAL S2
water (7g)
1 (2g) + water (3.6g) Hard, quite smooth

DEVELOPMENT
S3 4 (3g) + 3 (1g) Hard, rough, papery
S4 6 (8g) +2 (2g) Very hard, dark brown, smooth
S5 4, air drying Very hard, shrank more than 5, plastic-
like, cracked a lot
S6 5, air drying Very hard, shrank, cracked a lot
S7 6, air drying Very thin, brittle, cracked, similar texture
as colour coatings

Then, dried composites of the executed experiments were placed in the water for
several days to test whether they would become soft again, return to the previous
state or deteriorate, as it is expected of cellulose-based materials.

12 13
2. Cellulose-based Material Development

RESULTS After the material composites dried, their hardness and shrinkage were evaluated
through observation and breaking tests, performed with hands. The results were
the following:

Hardness: blue sample < S1 < S4 < S3 < S5

Shrinkage: blue sample < others < S6, S7 < S5

Almost all resulting samples cracked, shrank or otherwise curved - the dry
outcomes were no longer planar. Extensive cracking and shrinkage were noticed
as the biggest challenges to overcome.

S2 S1

S4 S2 S1

S5 in the
water
S4 S3 S6

Expectedly, all samples deteriorated in water with exception of sample S5. To our
surprise, test sample S5 remained hard and did not disintegrate, but lost some of
its hardness and became slightly more fragile.

Sample S5 was hard and very similar to plastics. During drying, it shrank for almost
S7 S5 S5 half of its original size and consequently cracked severely. Due to its resistance
in water and extreme hardness, it was recognized as a material worth exploring
further.
14 15
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 2 RESULTS

To overcome the challenges of extensive cracking and shrinkage, we prepared

some experiments with sawdust, since we assumed that sawdust containing
lignin, would function as adhesive, preventing cracking, and would also decrease
shrinkage.

Before drying, the mixtures of samples were formed into planar patches with
different thicknesses – thick and thin patches to compare the results. The drying
was executed freely at room temperature in the laboratory. The results of each
experiment are shown in Table 3.

Table 3 S8 S9

Test Mixtures with Outcomes

sample sawdust
S8 4 (20g) + sawdust Thin sample: brittle, fragile, curved, almost no
(2.5g) shrinkage
Thick sample: brittle, fragile, less curved,
almost no shrinkage
S9 6 (13g) + sawdust More brittle than S8, very fragile, quite soft, a
(2.5g) little bit flexible, cracked
S10 5 (20g) + sawdust More difficult to break than S9 and harder
(2.5g) than S9, cracked S10

Again, the final hardness of the outcomes was evaluated through observation and
breaking tests, performed with hands, and compared with sample S5. The results
were the following:

Hardness: S9 < S8 < S10 < S5

All the outcomes from experiments with sawdust mixtures were too brittle to be
compelling for further development. The sawdust did not function as adhesive
despite the lignin containment but did somehow limit the cracking rate.
16 17
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 3 RESULTS

Focusing on extreme hardness of sample S5 from experimentation phase 1, we

tested its possibility of drying in different shapes, such as hollow tube, small sphere
and curved mould, since the success of such experiment could open many new
possible applications in construction or food industry. We additionally questioned
the effects of the shape on the cracking and shrinkage ratio.

The air drying was executed at room temperature in the laboratory. The results are
presented in Table 4.

Table 4 S11 S12

Test Shape testing Outcomes

sample
S11 Sample 4 placed in No control over shrinkage, cracked severely
the round mould
S12 Sample 4 applied The fabric curved because of the cellulose
to the tulle fabric shrinkage - a very nice visual effect, but the
shrinkage left colour marks on the fabric.
S13 Sample 4 applied The sponge bent because of the cellulose S13 S14
to the sponge shrinkage, otherwise, the material cracked.
S14 Sample 4 placed No results
in the hole on the
sponge
S15 Sample 4 formed Cracked immensely, the hollow tube was not
as a hollow tube formed
S16 Sample 4 applied Cracked severely
to the surface of
the balloon

S15 S16
18 19
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 4

All of the test samples from this experimentation phase cracked and shrank
immensely, no matter the shape. Therefore, the correlation between shape,
shrinkage and cracking could not be claimed with no precise measurements. None
of the results was useful for further refinement. Immense shrinkage and cracking
remained our main problems when trying to develop a hard, plastic-like material.
The sample S12 (unbleached MCC gel applied on the tulle fabric) was visually
very interesting, but apart from artistic explorations, we could not think of any
functional applications.
In the following experimentation phase, the focus was on experimentation with
natural pigments and fragrances. The aspiration was to either develop a hard,
coloured material and scented material or a material that could be used for
colourful pencils or chalks.
The preparation of tests was done in the same manner as in previous experiments.
Before drying, the mixtures of samples were formed into planar patches with
different thicknesses – thick and thin patches to compare the results. The drying
was executed freely at room temperature in the laboratory. The results of each
experiment are shown in Table 5.

Table 5

Test Mixtures with natural pigments Outcomes

sample
S17 1 (2g) +6 (10g) + 5 (5g) + beetroot powder Hard, brittle
(7.5g)
S18 6 (13g) + 2 (3g) + chilli powder (5g) Hard, brittle
S19 Orange peel powder (1.3g) + dry yellow Very hard, 10%
pigment (1g) +5 (2.75g) +6 (11g) shrinkage, brittle
S20 Orange peel powder (1.3g) + dry yellow Hard, brittle
pigment (1g) +5 (2.75g) +6 (11g) + 5 (3g)

20 21
2. Cellulose-based Material Development

RESULTS

S17 S18

S19

Only sample S19 showed a bit of potential as a scented material. When burnt, it
smelled like orange, but the smell was not pungent enough. All the other materials
produced throughout this experimentation phase were successfully coloured but
were too brittle to be utilized for colour pencils or chalks.

S19 S20

22 23
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 5

In this experimentation phase we focused on combination of MCC and various Table 6

fibres in order to develop stronger and more flexible materials that would not
crack. Test sample Mixtures with fibres Outcomes
The preparation of tests was done in the same manner as in previous experiments.
Before drying, the mixtures of samples were formed into planar patches. The air S21 6 (10g) + blue fibres Plastic-like, brittle, limited
drying was executed at room temperature in the laboratory. The results of each (1.5g) + water (31g) flexibility, very smooth surface
experiment are shown in Table 6. S22 Blue fibres (2g) + 6 (7g) Hard, 20% shrinkage, curved
+ 2 (7g) + MS17 (1g)
S23 Blue fibres (2g) + 6 (7g) Hard, limited flexibility and
+ 2 (7g) shrinkage
S24 Blue fibres (2g) + 6 (7g) Very brittle, stiff, curved, very
+ 2 (7g) + MS17 (1g) + difficult to tear apart
MS19 + white PLA fibres
(2g)
S25 MS18 + MS17 + 5 (1g) Hard, brittle, 10% shrinkage, only
one side of the sample was
coloured (before drying, the
whole sample was coloured)
S26 4 + white PLA fibres Some shrinkage, but no cracking,
limited flexibility, fibres visible on
the surface
S27 6 + yellow fibres Inconsistent material, brittle,
difficult to tear apart
S28 4 applied on sponge Sponge curved because of the
shrinkage of the material sample
4
S29 Mixture of everything The hardest outcome yet, brittle,
we used in this curved
experimentation phase

24 25
2. Cellulose-based Material Development

RESULTS

S21 S22 S27 S28

S23 S24 S29

No photo Test samples with fibres were mostly hard and brittle with some flexibility in
specific cases, but neither of the outcomes was recognized as a composite
material with further potential. The resulting textures were mostly aesthetically
interesting for artistic applications. Fibres prevented extensive cracking of the
samples.

S25 S26
26 27
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 6 RESULTS

The experimentation continued with the search for a suitable substance that
could prevent cracking or even decrease shrinkage while drying the test samples.
Therefore, we experimented with white PLA fibres and wood glue.
The preparation of test samples was done in the same manner as in previous
experiments. The air drying was executed at the room temperature in the
laboratory. The results of each experiment are shown in Table 7.

Table 7 S30 S31

Test Material reinforcement with Outcomes

sample PLA fibres
S30 4 (10g) + water (7g)
MS30 further applied as a
coating onto the samples from
previous experiments
S31 4 (10g) + white PLA fibres (1g)
S32 4 (10g) + wood glue (3g)
The coating slightly increased the
strength of the material - it was
more difficult to break the sample
A little bit flexible, but still brittle,
very difficult to tear apart
Really flexible, limited shrinkage S32

28 29
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 7

The test sample S32 (a mixture of wood glue and material sample 4) was
successful in terms of achieving limited flexibility and cracking prevention. It
inspired us to think about natural adhesive materials, such as resin and sap that
could be utilized in further material experimentation. Wood glue enabled limited
flexibility of the material and prevented cracking.
Sample S31 with PLA fibres attained some flexibility and did not crack much. It was
strong and very difficult to tear apart but was not considered to be compelling for
further exploration.
In the cuisine, variations of starch are often used to stick different ingredients
together. Since starch is a natural material with adhesive capabilities, we thought
it could represent a sustainable alternative to wood glue and similarly prevent
cracking.
The preparation of test samples was done in the same manner as in previous
experiments. The air drying was executed at room temperature in the laboratory.
The results of each experiment are shown in Table 8.
Table 8

Test Mixtures with Outcomes

sample starch
S33 Corn starch (5g)
+ 4 (5g) + water
(3.5g)
S34 Potato starch (5g)
+ 4 (5g)
S35 Corn starch (5g)
+ 4 (5g) + water
(5g)
S36 1 (5g) + lignin (5g) Hard but very brittle samples, that turned to
+ water (13.5g) powder under pressure. Approximately 10%
shrinkage and severe cracking.
S37 MS35 (5g) + corn
starch (1g)
S38 6 (10g) + potato
starch (5g)
S39 Lignin (3g) +
potato starch (3g)
S40 1 (5g) + lignin (5g)
+ corn starch (5g)
30 31
2. Cellulose-based Material Development

RESULTS

S33 S34 S39 S40

Experiments with corn and potato starch were not successful, because all of the
samples transmuted into powder under pressure. In addition, the samples were too
brittle to have any potential for further development. Starch did not function as an
adhesive material, but only intensified materials’ brittleness.

S35 S36

No photo

S37 S38
32 33
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 8

Our focus shifted from testing hard materials towards developing materials that S44 6 (20g) + water (30g) + Soft, flexible and could be folded easily
are soft, flexible and porous. In connection to that, we replaced corn and potato rice starch (10g) + wood while wet; when dry, hard and kept the
starch with rice starch, wood glue and glycerine in order to achieve some flexibility glue (15g) given shape
of the material and prevent extreme cracking. S45 6 (15g) +1 (1g) + rice starch Very fragile, but did not crack
The preparation of test samples was done in the same manner as in previous (3g) + glycerine (6g)
experiments, but in this experimentation phase, drying was either initially executed S46 6 (15g) + 1 (6g) + water No shrinkage, very smooth and glossy
in a frying pan and later freely at room temperature or in a preheated oven at 60° (10g) + rice starch (3g) + surface on the side that was in contact
C. The results of each experiment are shown in Table 9. glycerine (6g) with the glass surface; plastic-like, a
little bit flexible
S47 1 (40g) + water (25g) + After drying in the pan soft, but when
Table 9 wood glue (30g) totally dry, hard
Test Mixtures with rice starch, Outcomes S48 6 (10g) + water (5g) + Very brittle, cracked
sample wood glue and glycerine wood glue (5g)
S41 6 (15g) + rice starch (10g) Sample expanded like an air-bag, brown
+ wood glue (10g) + some coloured, brittle
PLA fibre

Drying for 1h at 100°C in an

oven and then drying for
30min at 220°C in an oven
S42 6 (15g) + rice starch (10g) Sample did not expand, but shrank; it
+ wood glue (10g) was brittle and brown coloured.

Drying for 1h on 100°C in

the oven and then drying
for 30min on 220°C in the
oven
S43 6 (22g) + water (30g) +rice
starch (10g) + wood glue
(2g)
Thick sample: the sample did not dry
completely, the middle layer was sticky,
but the material still cracked
Thin sample (1mm): cracked severely
before even dried

34 35
2. Cellulose-based Material Development

RESULTS

S41 S42 S47

S43 S44 S41

Mixtures with rice starch and wood glue offered some interesting outcomes in
the case of the test sample S41 which expanded. Since this was the first time
expansion happened, we thought that such material should be explored further.

S45 S46
36 37
2. Cellulose-based Material Development
S44
The sample S44 was promising because of the form that could be performed
before the sample dried completely. The softness of the sample right after drying
in the frying pan enabled us to shape the material in the specific form which
persisted even when the material dried completely.
38
S46
Sample S46 was interesting due to its glossy, smooth surface and no shrinkage.
Other resulting samples of this experimentation phase were flat and did not curve.
Furthermore, their shrinkage was limited. Glycerine functioned as a binder that
softened materials, provided some flexibility and prevented cracking.
39
2. Cellulose-based Material Development

EXPERIMENTATION PHASE 9

Despite having done many experiments, our main problems while developing new Table 10
cellulose-based materials, that could be applicable to our initial ideas stated in the
counter brief, still remained: Test Foaming with MCC Outcomes
sample
• Big shrinkage ratio and consequent cracking S49 Water (300ml) + CMC, yellowish gel
• Curving of the dry samples carboxymethyl cellulose (low
viscosity, 9g)
At this point, our exploration was redirected towards cellulose-based foams, S50 CMC + SDS White foaming base; when dry,
since we started thinking about applications in furniture, protective packaging or looked similar as gelatine
acoustic industry. With the help of laboratory assistant Ines, we conducted some S51 MS50 (80g) + 3 (10g) Foamed a little, quite hard, almost
foaming experiments. no shrinkage; weighed 1.27g
S52 MS50 (80g) + 1 (5g) Only the bottom layer foamed; non-
The foaming base we prepared, was a mixture of sodium dodecyl sulfate (SDS) homogeneous with uneven surface
and carboxymethyl cellulose (CMC). SDS is a synthetic organic compound that is S53 MS51 (minus 18g) + 3 (10g) Less porous but harder than
used in many domestic cleaning detergents, personal hygiene and cosmetic. With S51, almost no shrinkage, curved
professional guidance, we also synthesized CMC, a cellulose gum that functions like surface; weighed 2.25g
glue. S54 6 (52g) + 3 (22g) + CMC (15g) Quite a nice foam, some flexibility,
+ SDS no shrinkage; weighed 11.81g
The preparation of test samples was done in the same manner as in previous S55 MS50 (20g) + 2 (5g) Very hard, not flexible at all, almost
experiments, but in this experimentation phase, drying was executed in a no shrinkage, foaming did not occur;
preheated oven at 60°C overnight. The results of each experiment are shown in weighed 1.62g
Table 10 on the next page. S56 4 (70g) + CMC (50g) 65% shrinkage, curved

S57 CMC (15g) + 1 (4g) 30% shrinkage, very brittle; weighed

4.25g
S58 CMC (20g) + 6 (20g) 80% shrinkage, hard but brittle,
plastic-like
S59 CMC (40g) + 1 (5g) + lignin Cracked, fragile, powdery
(5g)
S60 SDS + 6 (30g) Foamed, severely cracked, very
porous

40 41
2. Cellulose-based Material Development

RESULTS

S51
S52 S59 S60

S53 S60

S54

No photo

S56
S55

Foaming experiments were successful since we managed to produce hard and

light foams, which were simultaneously fully biodegradable. CMC functioned as a
S57 S58 cohesive material and SDS performed as a foaming initiator.
42 43
1. Introduction of the Material Development Process

EXPERIMENTATION PHASE 10 EXPERIMENTATION PHASE 11

Attempting to develop a flexible material that would not crack, we conducted a test
utilizing the CaCl2 solution prepared as stated below:
Water (1l) + CaCl2 (200g) CaCl2(aq)
The latter was used for experiments with test samples shown in Table 11. The
samples were put into the solution for 2 hours before they were placed in a
preheated oven at 60°C overnight.
In this experimentation phase, we replicated the successful foaming experiments
and formed test samples with different thicknesses to test whether the thickness
of the sample affects the foaming ratio. Additionally, some foaming mixture was
placed in a rounded mould. Attempting to increase the foaming to create even
lighter material, we also conducted the following experiment described in Table 12.
The preparation of test samples was done in the same manner as in previous
experiments. The drying was executed in a preheated oven at 60°C overnight.

Table 11 Table 12

Test Mixtures with NFC Outcomes Test Replicated foaming with MCC Outcomes
sample sample
S61 NFC (100g, nanocrystalline cellulose) Big shrinkage, curved a lot, a S64 6 (106g) + 3 (35g) + CMC (30g) + Thick sample: Hard and light
+ grinded pulp fibre (2g) little bit flexible SDS (1g) foam
S62 NFC (50g) + grinded pulp fibre (1g) + Really hard, shrank and Thin sample: Hard and light
1 (5g) curved foam
S63 NFC (50g) + grinded pulp fibre (1g) + The hardest, shrank and
1 (10g) curved

RESULTS
The conducted experiments of this experimentation phase did not result in flexible
materials, as it was planned. The samples were hard, brittle and curved a lot.

44 45
2. Cellulose-based Material Development

RESULTS EXPERIMENTATION PHASE 12

Trying to achieve aesthetically flawless material results that could be visible in

applications such as acoustic panels, we prepared foaming mixtures with natural
pigments from charcoal, red beans and orange peel.

The preparation of test samples was done in the same manner as in previous
experiments and drying was executed in a preheated oven at 60°C overnight. The
results are shown in Table 13.

Table 13

S64 S64 Test Foaming mixtures with Outcomes

sample natural pigments
S65 6 (30g) +3 (70g) + CMC (120g) + /
SDS + water (20g)
The thickness of the sample S64 did not affect the foaming ratio, since both, a thick
and thin sample, foamed equally, but on the other hand, did influence the drying S66 MS65 + charcoal Foamed successfully, fully
rate, as the thinner sample dried more rapidly. Shaped in a flat square form mixed
S67 MS65 + red bean powder Foamed successfully, had a
In connection to drying various foams, the main problem that was recognised certain smell
through entire experimentation process, was ensuring equal drying ratio
S68 MS65 + orange peel powder Foamed successfully, had a
throughout entire sample. In the case of the mixture MS64 placed in a rounded certain smell
mould, where the top surface was the only surface directly exposed to air, the
sample did not dry equally fast, which resulted in non-homogeneous material with S69 MS65+ sawdust Foamed successfully, fully
noticeable holes. Otherwise, dry sample kept the shape of the mould, but was too mixed
porous, which lead us to conclusion, that the material contained too little dry MCC
(material sample 3).

46 47
2. Cellulose-based Material Development

RESULTS EXPERIMENTATION PHASE 13

Further foaming experiments, aiming to achieve even lighter foams, were

conducted with the combination of NFC, MCC and super fine pulp fibres.
The preparation of test samples was done in the same manner as in previous
experiments. The drying was executed in a preheated oven at 60°C overnight. The
results are shown in Table 14.

Table 14

Test Foaming with NFC Outcomes

sample
S66 S67 S70 CMC (45g) + NFC (20g) Hard foam, no shrinkage
+ SDS
S71 MS70 (5g) + super fine Hard foam, no shrinkage
pulp (0.5g) + water (5g)
S72 CMC (50g) + NFC (15g) Hard foam, some shrinkage, less porous
+ 6 (30g) + SDS than S70 and S71
S73 MS72 (20g) + super fine Some shrinkage, hard foam
pulp (0.5g)
S74 MS72 (10.5g) + 2 (5g) Shrank, uneven surface, inconsistent
material, hard foam
S75 MS74 (some) + 1 (3g) Very brittle and dry foam, the hardest
among samples of this experimentation
phase
S68 S69

All the samples foamed successfully, so additional weight as a consequence of

added natural pigments did not prevent the foaming. The results were coloured,
flat and did not crack.

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2. Cellulose-based Material Development

RESULTS

Foaming experiments with NFC mostly resulted in less homogeneous hard foams
with uneven surface and similar properties. In contrast to previous foaming tests
some shrinkage was noticed. None of the samples had fundamentally better
properties than the foamed test samples from previous experimentation phases.
Due to the aims of the task, we decided to continue with development of foams
mostly based on only MCC instead of foams containing also NFC.

S70 S71

S72 S73

S74 S75
50 51
1. Introduction of the Material Development Process

EXPERIMENTATION PHASE 14

In order to provide uniform samples with analogous shape for the final exhibition S82 6 (52g) + 3 (22g) + CMC (15g) + SDS 10% shrinkage, very hard, no
of the course, we replicated the most interesting experiments from previous + sawdust cracks, rough surface, a little
experimentation phases, which was also a test of our documentation technique. bit curved
Additionally, some new experiments with glycerine, a polyol compound for providing S83 6 (52g) + 3 (22g) + CMC (15g) + SDS Hard foam, no shrinkage,
smoothness in cosmetic industry, were conducted. The latter performed well as a + charcoal almost no curvature, grey, the
binder providing more flexibility and preventing cracking in previous experiments. texture of the mesh persisted
Mesh was placed on the top of
The preparation of test samples was done in the same manner as in previous the sample to test whether that is
experiments and drying was executed in a preheated oven at 60°C overnight. The a feasible way to make a certain
results are shown in Table 15. texture
S84 6 (52g) + 3 (22g) + CMC (15g) + SDS No foaming, 5% shrinkage,
+ lignin some curvature, the sample
Table 15 became thin, hard
S85 6 (52g) + 3 (22g) + CMC (15g) + SDS Soft foam, flexible, no
Test Mixtures with glycerine Outcomes + glycerine (10g) shrinkage, no curvature
sample
S76 4 (30g) + sawdust (5g) +CMC (10g) Hard, 20% shrinkage, no S86 CMC (60g) + SDS + lignin (4g) + Hard, 5% shrinkage, no
cracking, did not curve much, rice starch (2g) + glycerine (4g) + cracking, curved, uneven
rough surface 1 (5g) surface
S77 4 (40g) + corn starch (10g) +CMC Very hard, cracked severely S87 CMC Transparent, plastic-like, fragile,
(10g) very thin but before drying it
was thick
S78 6 (52g) + 3 (22g) + CMC (15g) + SDS Hard, 10% shrinkage, did not
+ charcoal curve much, charcoal and foam
still in two separate layers
S79 6 (65g) + 1 (12g) + glycerine (6.5g) Hard, fragile, cracked, curved,
uneven surface
S80 MS19 (18g) + glycerine (7g) Limited flexibility, some
shrinkage, cracked a little,
curved, smelly
S81 MS46 (some) + glycerine (10g) High density, similar material to
dough

52 53
2. Cellulose-based Material Development

RESULTS

S76 S77 S82 S83

S78 S79 S84 S85

S80 S81 S86 S87

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2. Cellulose-based Material Development

Our documentation technique turned out to be successful since the replicated

samples for exhibiting means behaved in the same manner as in previously
conducted experiments.

S85

The majority of test samples produced with glycerine did not crack, curve and
shrink or did shrink only limitedly. Sample S85 was the first soft foam we were able
to produce.

S83

Sample S83 was dried in a preheated oven with a mash placed on the top of the
material. This test revealed that the foaming mixture was dense enough to keep
the texture of the mesh after drying, meaning, that many aesthetical interventions
regarding texture or shape could be performed.

S76

S76 was the first MCC mixture with sawdust that did not crack and was less brittle.
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2. Cellulose-based Material Development

EXPERIMENTATION PHASE 15

Considering application of MCC-based foams as acoustic panels, the test with S91 MS54 applied between The hard foam stuck seamlessly on
waves-like curved mould was conducted to find out whether the foam could be 1mm thick wooden covers both wooden covers. No glue was
shaped in a stable 3D form. Moreover, natural pigments were added to the foaming added. Top cover slightly bent.
mixture in order to produce aesthetically more appealing material patterns. S92 MS54 (495g) + glycerine Thick sample: soft foam, no shrinkage,
(30g) + orange peel a little bit flexible, quite smooth
Furthermore, we tested our concept of MCC-based foam as the core material in powder surface, smell of orange
composite wooden furniture. In case of success, such furniture could be much Thin sample: soft foam, no shrinkage,
lighter and more sustainable. We prepared experiments with different thicknesses flexible, smooth, leather-like
of the wooden layers, which were used as a top and bottom covers of the foaming S93 MS54 (495g) + glycerine Soft foam, no shrinkage, flexible,
mixture. (30g) + charcoal smooth, leather-like, shaped like mould
Placed on the mould with
Additionally, some glycerine and orange-peel powder were added to the foaming bulges
mixture, since the glycerine made test samples from previous experiments retain S94 MS54 (50g) + hand Very soft, very light, porous, no
more moisture, which could consequentially mean more intensive orange smell. dishwashing (4g) + water shrinkage
(55g)
The preparation of test samples was done in the same manner as in previous S95 MS94 + orange peel Less soft and more porous than S93, no
experiments and drying was executed in a preheated oven at 60⁰C overnight. The powder shrinkage
results are shown in Table 16. S96 MS94 Very light and hard foam, wavy surface
Placed on the wave-like was not perfect
mould
Table 16 S97 MS96 (102g) + glycerine Soft foam with wavy surface, some
(20g) flexibility
Test Form testing Outcomes Placed on the wave-like
sample mould
S88 MS54 applied on wave-like Hard foam, 20% shrinkage, non-
mould homogenous material, curved, Lastly, the MCC-based foam sample S54 was placed into the water to test whether
inconsistent 3D form the hard foam actually deteriorates and how fast this process happens.
S89 MS54 + charcoal Hard foam, colourful patterns
Charcoal mixed with MS54
and applied in colourful
patterns
S90 MS54 applied between Thin wooden veneer covers cracked
wooden veneer covers and curved, the whole sample shrank
in thickness for 40 %
58 59
2. Cellulose-based Material Development

RESULTS

S88 S89 S93 S94

S90 S91 S95 S96

S92 thick S92 thin S97

60 61
2. Cellulose-based Material Development

S89 S92 thin

Samples S89 and S93 confirmed that MCC-based foam can be coloured in certain Thin sample S92 was very interesting due to its flexibility and smooth surface.
patterns and given a specific texture. On the other hand, the outcome of the When bending the material, its structure reminded us of leather, but we could not
experiment with wave-like mould, resulting in sample S88, was unsuccessful, think of any viable applications.
meaning, that the MCC-based foams could not be shaped in profound forms.

62 63
2. Cellulose-based Material Development

S91 S94

MCC-based foam applied in between thick wooden covers (S91) stuck successfully Sample S94 was the lightest and softest MCC-based foam we were able to
on the wood, without adding any glue and was additionally strong and light. produce.

64 65
2. Cellulose-based Material Development

3 POTENTIAL
APPLICATIONS
As expected, MCC-based foam sample S54 placed into the water disintegrated into
small particles immediately.

66 67
3. Potential Applications
The entire process of cellulose-based material experimentation in the
laboratory was simultaneously underpinned by a systematic idea generation of
possible application areas for the material in development. At the end of each
experimentation phase, we had to decide, which material, if any, had enough
potential for further refinement. Decision making was done with the consideration
of possible application areas, that were stated in counter brief and generated
through initial playful exploration of material’s properties. The leading product
concepts that directed this decision-making process were acoustic panels,
protective product packaging, redesigned material for furniture and scented plates
for the interior. Those concepts are briefly explained on the following pages and
mostly utilize the resulting material of the sample S54.
68
ACOUSTIC PANELS
Due to many open-office arrangements, there is a growing need for acoustic
panels and movable space dividers, that absorb noise and at the same time provide
some privacy. Hard and porous MCC-based foam, that we managed to produce,
offered a new opportunity for such products with an important improvement -
biodegradability.
Contemplating this product concept, we decided to test whether the MCC-based
foam could be coloured and formed in 3D shape. In that way, the material could be
applied to the acoustic panels without supplementary covers. So far, we succeeded
only in colouring and establishing minor textures, since the tests with shaping
the MCC-based foams in profound forms resulted in non-homogeneous material
that shrank immensely. In contrast, we can confirm, that establishment of certain
texture on the surface of the foam can be performed as presented in samples S83
and S93.
The core material used for this area of application S54, a solid hard foam, performs
adequately, but some further experiments should be conducted to perfect
the material and ensure desired acoustic properties, moisture resistance and
furthermore gain more control over shrinkage and shaping.
S54
69
3. Potential Applications

RENDERINGS

Acoustic panels with a wavy surface

70 71
3. Potential Applications

72 73
3. Potential Applications

PROTECTIVE PACKAGING

MCC-based biodegradable foam (S54) could, on the other hand, be used as a

protective material in the packaging of more valuable objects, where it could act as
a sustainable replacement of synthetic Styrofoam.

Apart from further tests regarding the mechanical and thermal properties of MCC-
based foam that should be conducted, processing and shaping of this material
must also be taken into consideration in order to be able to thoroughly compare
the material with Styrofoam and other synthetic materials with similar properties.

S54
74 75
3. Potential Applications

76 77
3. Potential Applications

78 79
3. Potential Applications

REDESIGNED MATERIAL FOR FURNITURE

A hard, biodegradable foam (S54) could also be utilized as a core material in

composited wooden furniture or doors since it was structurally strong enough
to be positioned between 2 wooden layers as shown in the scheme 1 below and
proved with sample S91. It is important to emphasise that no glue was needed
to stick wooden and foamed layers together since wet MCC-based foam stuck
intensively on the wooden layer during drying. The same result of attaching MCC-
based foam on other materials was observed in combination with ceramics and
glass. Most importantly, furniture produced with such composite material (S91)
without any glue, would be lighter, easier to recycle and less harming for the
environment.

Rapid prototyping enabled us to test the feasibility of our initial concepts, but
additional experiments in a bigger scale are needed to assess the bending
of the top layer of the composite material S91, which was spotted during our
experimentation process. Moreover, the thickness and quality of wooden layers, or
possibly even other materials, should be examined and further prototyped to refine
the concept.

Scheme 1: Section view of the redesigned composite material for furniture S91

Wooden cover layer

MCC-based foam

Wooden cover layer

80 81
3. Potential Applications

SCENTED PLATE FOR INTERIOR

A scented plate was a product concept for the interior. The aim was to develop
biodegradable material that would have a certain smell when burnt or poured over
with water. The product could be used as long as it would provide some scent and
after that simply discarded to deteriorate. We mainly experimented with orange
peel powder, which led us to results that were not as pungent as initially targeted,
but this barrier could be overcome with further experimentation.

S19
82 83
3. Potential Applications

OTHER APPLICATIONS

Many materials that were developed during our experimentation probably have
further potential for a wide range of applications, but given the frame of roughly six
weeks, we narrowed our field of research on only some of them.

Above mentioned MCC-based foam (S54) could also be used for portable boxes
for transportation of pets, such as cats, rabbits, etc.; or even as an insulator in the
construction industry. Moreover, the MCC-based foam could be shaped into a toy
for hamsters, providing them with an additional food source.

4 OVERVIEW

84 85
4. Overview

Our project dealt with material exploration of 6 MCC variations that served as
inspiration towards a systematic idea generation of possible material application
areas that were finally developed into product concepts.

The experimentation process resulted in 97 material samples, from which MCC-

based hard foam was recognised as the material with the most potential.

Supporting the playful material experimentation and rapid prototyping, ideas for
potential applications were generated, followed by product concepts development.
Concepts such as acoustic panels, protective packaging and a core material in
composite wooden furniture or doors, fully utilized properties of MCC-based hard
foams and were feasible enough to prototype. The hands-on approach enabled
us to gain a deeper understanding of the material and recognise viable product
concepts sooner.

Having done many experiments, we can claim that the knowledge about
MCC-based foam’s performance in different manufacturing processes, the
characteristics of the processed material, and its properties is still limited and
needs to be expanded. Therefore, additional tests must be conducted to further
develop the material and perfect it to the point, where successful application would
be safely realisable.

To conclude, working on this project enabled us to attain a deeper understanding

of material research and development process, not only from a designer’s
perspective but also from a professional researcher’s point of view, which is a
beneficial skill for our future professional career in trans-disciplinary teamwork.

86 87
REFERENCES

Fao.org. (1996). Microcrystalline cellulose. [online] Available at: http://www.fao.

org/3/w6355e/w6355e0l.htm [Accessed 16 Mar. 2019].

Finnish Forest Association. (2017). A new method to produce microcrystalline

cellulose - Finnish Forest Association. [online] Available at: https://smy.fi/en/
products-services/a-new-method-to-produce-microcrystalline-cellulose/
[Accessed 16 Mar. 2019].