Biofoams Poised to Revolutionise Sustainable Construction

The construction industry is on the brink of a transformation that could alter the way we build, breathe, and live. Imagine buildings that autonomously adjust to environmental changes, expanding and contracting to control airflow, almost as if they are alive.

This is no longer just a futuristic concept; a ground-breaking project led by European researchers is turning this idea into a tangible reality. Over the next three years, a team of experts from Finland, Germany, and Italy will collaborate to create passive ventilation systems from a sustainable, wood-based biofoam.

This innovation has the potential to significantly reduce the construction industry’s carbon footprint and introduce a new era of adaptive, eco-friendly architecture.

Transforming Construction with Biofoams

The project, known as Archibiofoam, is a joint effort involving Aalto University in Finland, the University of Stuttgart in Germany, and the University of Milan in Italy. Recently, this ambitious initiative received a significant boost with a €3.4 million grant from the European Innovation Council’s Pathfinder program. The goal? To prove that wood-based biofoams can be a viable alternative to traditional building materials like concrete, steel, and glass.

Juha Koivisto, a leading researcher from Aalto University, is confident that biofoams derived from extruded wood cellulose can revolutionise the construction industry. He explain: “Not only will we show that wood-based foam can be used as a replacement material, but we will also demonstrate its unique ability to respond to environmental factors like heat and humidity, enabling the passive heating and cooling of buildings.”

Koivisto’s team is focused on creating exterior building facades with porthole-like openings that can autonomously open and close in response to the environment. If successful, this innovation could drastically reduce the carbon footprint of buildings, offering a sustainable alternative to the highly polluting materials currently in use.

The Environmental Impact of Traditional Construction

It’s no secret that the construction industry is a major contributor to global pollution. In fact, it’s responsible for approximately 40% of annual global emissions. The production and use of materials like concrete, steel, and glass are resource-intensive and non-renewable, leading to significant environmental degradation. However, the introduction of biofoams could change all that.

Biofoams are composed of 90% air, making them incredibly lightweight, yet they possess a strength comparable to traditional construction materials. More importantly, these foams are biodegradable and align with the principles of the circular economy, ensuring that they can be reused or recycled at the end of their life cycle.

Koivisto notes: “The scientific community has known for some time that the structural integrity of these biofoams is competitive with other construction materials, but it hasn’t been tested to its full potential.”

He envisions a future where buildings, much like the organic designs of Gaudí’s Barcelona, can naturally ventilate themselves without the need for energy-intensive systems.

The Role of 4D Printing in Adaptive Architecture

A key component of the Archibiofoam project is the use of advanced 4D printing technology, a process that allows printed objects to autonomously transform in response to environmental stimuli. This innovative approach to digital design and robotic fabrication is spearheaded by Tiffany Cheng, research group leader at the University of Stuttgart’s Institute for Computational Design and Construction.

Cheng’s team is responsible for fine-tuning the massive 4D printer used in the project. This technology allows for the creation of large-scale biofoam structures that can adapt to changes in heat and humidity. By tailoring the manufacturing process to meet the specific functional requirements of building components, Cheng’s team aims to unlock the full performance potential of wood-based biofoams.

“Robotic additive fabrication is particularly well-suited for structuring materials at high resolution, thereby unlocking the performance potential of wood-based biofoams at a large scale,” says Cheng. “Our goal is to create a mono-material system that meets multiple functional requirements, such as load-bearing capacity and adaptive ventilation.”

Harnessing the Power of Algorithms for Smart Design

The University of Milan’s contribution to the Archibiofoam project focuses on the digital modelling aspect of the biofoam structures. Led by Professor Stefano Zapperi, the Milan team is developing proprietary software that will enable the automatic generation of 3D models. These models will be optimised for specific design parameters, such as heat and humidity sensitivity, to ensure the most efficient and controllable results.

“We are currently witnessing a revolution in structural design thanks to algorithms that can find the most effective geometry for a desired function,” explains Zapperi. “Throughout the Archibiofoam project, we plan to expand the capabilities of our software and adapt it to the physical characteristics of the biofoam and the needs of the building sector.”

Zapperi envisions a future where architects can simply input their design requirements into a computer, and the software will generate a ready-to-fabricate 3D model. This approach could streamline the design process and ensure that buildings are optimised for both sustainability and functionality.

Industrial Potential and Future Prospects

While the Archibiofoam project is still in its early stages, the biofoam material itself has been under development for over a decade. Initially researched as a climate-friendly packing material, biofoams have since demonstrated significant potential in the construction industry. Woamy, an industrial partner and Aalto University spinoff, has already built a business around biofoam technology and is planning to establish its first pilot factory by 2027.

Susanna Partanen, CEO of Woamy, is optimistic about the future of biofoams in construction. “As an Aalto University spinoff, Woamy is at the forefront of developing this novel biofoam technology. Our deep roots in this innovation are vital in bringing the Archibiofoam project to life,” she says. “Through this collaboration, we aim to showcase how Woamy biofoam can not only transform the packaging industry but the construction industry as well.”

The industrial potential of biofoams extends beyond their environmental benefits. By reducing the reliance on non-renewable resources and lowering the carbon footprint of buildings, biofoams could become a cornerstone of sustainable construction. The next few years will be critical in determining whether this material can live up to its promise.

A Future Built on Innovation

The Archibiofoam project represents a bold step forward in the pursuit of sustainable construction practices. By harnessing the power of biofoams, 4D printing, and advanced algorithms, this collaborative effort is poised to deliver a new generation of adaptive, eco-friendly buildings. The implications for the construction industry are profound, offering a pathway to significantly reduce global emissions and create structures that are in harmony with the environment.

As the world grapples with the urgent need to address climate change, innovations like Archibiofoam offer hope for a more sustainable future. The success of this project could pave the way for broader adoption of bio-based materials in construction, ultimately leading to a greener, more resilient built environment.

In the coming years, we may very well see buildings that “breathe” as part of our urban landscapes—a testament to the power of innovation and the determination of researchers to create a better world for future generations.