Sustainable wood-based material for mass manufacturing without design limitations

Overview

Daika has developed a novel material that enables mass manufacturing of sustainable wood products without the design limitations and industrial constraints typically associated with traditional wood processing. The material is composed of recycled wood particles combined with a natural binder derived from wood (a type of cellulose). Both components are dispersed in an aqueous medium, free of hazardous solvents or volatile organic compounds, resulting in a highly viscous paste with flow characteristics similar to molten plastics. This paste can be used in standard molding and extrusion processes, opening new possibilities for sustainable manufacturing.

Technical specifications

Key features:

• Composition: Recycled wood particles as the primary loading material, combined with a natural cellulose-based binder
• Processing: Aqueous dispersion with no hazardous solvents or VOCs, producing a paste with viscosity and flow behavior comparable to molten plastics
• Manufacturing compatibility: Suitable for molding and extrusion using industrial machinery; initial proof-of-concept demonstrated on industrial molding machines
• Mechanical performance: Achieves densities up to 0.95 g/ml and strength up to 1500 MPa
• Natural wood properties: Retains thermal resistivity and acoustic characteristics inherent to wood
• Cost efficiency: The majority of the formulation is waste wood particles, keeping material costs low and applicable for industrial-scale manufacturing

Technology readiness level

The technology has been validated through an initial proof-of-concept on industrial molding machines and supported by a published academic study (originally focused on 3D printing). The scientific rationale and formulation details are protected through a PCT patent application, entering national phase in July 2020. Current R&D, supported by seed funding from the Israel Innovation Authority incubator program, is focused on rapid drying processes, repeatability (preventing warping and cracks), and composition optimization. Novel post-processing techniques are being evaluated with a strategic partner in the injection molding industry.