New Shell Lab

By Bo Knoblauch

Through interdisciplinary research and collaboration with local establishments in Bergen, a bioplastic material has been developed to utilize renewable resources and organic byproducts collected from the Norwegian shellfish industry. In addition to material development, a system for open-source manufacturing has been created to convert the bioplastic into seed-starting planters for agricultural purposes. New Shell Lab illustrates the possibility for designers to use rapid prototyping technologies to create sustainable materials from byproducts and renewable resources found in their own communities. The resulting design research, material development, and build guides for machinery will be published online in the Spring of 2020 as a resource for future designers and material developers.

The collection of organic waste collected from fish markets and restaurants provided a foundation for material development. Additional renewable resources, such as gum rosin from pine trees, allowed for the production of a 100% bio-based thermoplastic material.

Material development began with the identification of components that make up thermoplastic materials. These three components include the polymer, filler, and pigment. In standard practices for producing oil-based plastics, such as polypropylene, these components are made up of synthetic and inorganic compounds. To create a bio-based thermoplastic, organic alternatives must be identified to substitute inorganic compounds. Through identifying current renewable resources available in Norway, the two organic compounds selected for the bio-based material include gum rosin from pine trees and shell waste from shellfish.

To process the bio-based thermoplastic, two machines have been developed for open-source manufacturing. The Hammer Mill is designed to pulverize the raw shell waste into a powdered form for even consistency when used in production. Research included analyzing technical drawings from industrial hammer mills, as well as exploring open-source build plans from designers and makers online. The Injection Molding machine followed the same research process, where industrial injection molding machines were referenced as a starting point for machine design.

For the final stage of the project, the bioplastic material was intended to be used to produce seed-starting planters for agriculture, which aimed to promote ecological growth once biodegradability occurs. Agricultural research explored opportunities within regenerative agriculture processes and alternatives for single-use plastics in farming and gardening activities. In addition to the benefit of biodegradability, the calcium carbonate within the bio-based material has the ability to to neutralize the pH of acidic soils upon degradation. By researching current seed-starting planters on the market, the activity of seed-starting greatly influenced the form and utility of the planter’s design.

Bo Knoblauch (US)

Bo Knoblauch is an Industrial Designer who aims to create objects that can challenge existing production processes and materials. Through constant exploration and iteration, Knoblauch engages in a collaborative design process that combines interdisciplinary research with rapid prototyping and model making. After graduating from the Rhode Island School of Design In 2016, Knoblauch began working as an Industrial Designer in New York City for the furniture and housewares industry. To challenge traditional practices in Industrial Design, Knoblauch has used his postgraduate studies at the University of Bergen, Institute for Design, to identify opportunities for sustainable product development across product categories.