The promise of advanced materials

Tomorrow’s materials are engineering a product revolution at the very smallest of scales, well beyond what the eye can see through an optical microscope. What material can do is no longer being “discovered,” as it was in the past. 

Instead, “unnatural” substances are being invented by scientists around the world. Advances in nanotechnology, computer modelling, AI-driven materials informatics, and nature-inspired design are enabling engineers to manipulate the properties and functions of products in ways that seemed magical not so long ago. 

We have reached a point of mastery of materials that allow seemingly inanimate objects to be programmed with functions and characteristics at the molecular level to meet our needs. It is improving the sustainability of our products, mimicking the elegance of nature’s design, and changing the face of manufacturing.

Companies recognising the exponential growth potential of advanced materials can start developing products and manufacturing processes that help differentiate them from their competitors. Consider these three areas of innovation to understand the opportunities for advanced materials.

Sustainable alternatives to carbon-intensive materials

Almost all organisms depend upon oxygen and almost all material manufacturing processes emit greenhouse gases. This reality presents us with the challenge of how we can reduce CO2 and at the same time produce what the world needs. Unfortunately, recycling alone is not enough. These materials tend to be difficult to source, costly and require rigorous reprocessing. In addition, we need to look at the entire life cycle of the material, not just one stage. Consumers and business buyers are increasingly considering their carbon footprint when making purchasing and investment decisions. This suggests that sustainability has become an important aspect of business decision-making, which offers a huge market potential for companies to differentiate themselves with low- or zero-carbon products. 

Part of the answer is exploring new materials and many (creative) options made from renewable and specific biomass-derived raw materials. For a quirky example, consider the Shrilk bio monomer. Shrilk’s main ingredient is chitin, the substance that gives insects and crustaceans such as shrimp their hard shells. Chitin is the second most abundant organic substance on earth and can be processed into a plastic-like substance called chitosan. Combining chitosan with a natural silk protein called fibroin creates a laminate material that is stronger than aluminium.

Manufacturers can reduce their dependence on petroleum-based materials through upcycling. This means adding new ingredients to lower quality recycled materials to make them more valuable. A good example of this is the 10 billion water bottles produced every year. Suppose we want to depolymerize these water bottles (that is, break them down into their basic monomers). In this case, you can add new material components and repolymerize the new recipe (that is, combine all the base monomers back together) to create your own. The possibilities are endless; these recycled plastic bottles could become pillowcases or high-speed data center connectors.

Advanced products that use smart materials – Nature has the patent portfolio

In the current scenario, smart materials are emerging that can provide next-level functionality. These smart materials sense external stimuli such as temperature, strain, or current and respond predictably by changing shape, colour, or other properties. Intelligent materials rooted in nature respond to these stimuli by altering their internal structure and intrinsic properties (such as stiffness, strength, and energy absorption capacity) or optical properties (such as transparency and opacity). 

Imagine a ubiquitous material like concrete. Despite its strength and versatility, concrete cracks over time, requiring regular maintenance of the structure to maintain its integrity. Scientists have developed a new type of smart concrete that can self-repair with embedded bacteria. When the bacteria come into contact with water, they produce a lime substance that fills the cracks. Nature has proven to be an excellent source of inspiration for smart materials. After all, over millions of years of evolution, nature has developed its own patent portfolio.

Advanced printed materials and the era of mass nature-based customisation

Advances in 3D printing are already transforming manufacturing and design processes, but new advances in 3D printing materials will enable even more innovation. For example, new high-quality 3D printing materials can withstand temperatures up to 850 degrees Celsius, expanding the range of products that can be manufactured on demand and increasing the flexibility and economics of manufacturing in high-cost locations.

With manufacturers in many industries exploring what 3D printing technology can produce, logistics service providers are launching pilot programs to address the needs, possibilities, and adaptation of existing business models to 3D printing services, analysing alternatives. 3D printed components offer the same level of safety and stability as conventionally manufactured components but may be optimized for lower weight. For example, installing such components in an aircraft saves fuel and minimises CO2 emissions. In addition, products with new design freedom can be manufactured more quickly. It is much faster to print something off a computer screen than to carve a shape out of a solid block of hardened steel.

The development of new materials will accelerate the adoption of 3D printing, ultimately ushering in a new era of flexible manufacturing and mass customization where materials work hand-in-hand with design. Product designers imitate the teachings of nature, incorporating curved surfaces to optimise heat transfer and subtle topological shapes tested during evolution. We have reached a new level if we can design and manufacture like nature.

Putting your business on the exponential curve

Humanity and material history have evolved together. But until recently, we “discovered” natural materials and their properties by testing the things we made. The round houses of the Iron Age, the discovery of thatched roofs that could withstand the wet European winters, the chance discovery of concrete that enabled the Romans to build beautiful viaducts that stand today as witnesses to progress. We are moving through a golden period of exponential growth in our capabilities, enabling the next great leap forward in design. It will be fascinating to see where it takes us.

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