LifeCycled Materials

Medium density fiberboard (MDF) is an engineered sheet wood material that is widely used in housing and furniture construction around the globe. MDF is made by combining wood fibers with a resin glue and applying high temperature and pressure to form panels. In 2021, the MDF market size was estimated at more than 100 million cubic meters, with a projected compound annual growth rate (CAGR) of greater than 3.5% during the period of 2022-2027. The low cost of MDF compared to alternatives is a key driver of demand. 

We are tackling four problems associated with MDF: (1) The production of MDF depends on naturally-derived wood fiber as a raw material, which contributes to deforestation. (2) During production and use, the resin glue emits toxic chemicals such as formaldehyde and other volatile organic compounds (VOCs) that cause eye and lung irritation and even cancer. Adoption of stringent formaldehyde emission regulations in many countries is expected to hinder market growth. (3) When MDF is cut, sanded, or machined in any way it releases clouds of hazardous dust particles, and when MDF is drilled or screwed into it often splits. (4) MDF can only be disposed of via landfill or incineration. Landfill disposal contributes to the waste crisis, which has been exacerbated by China’s ban on imported municipal solid waste. Emissions from landfills and incinerators, such as methane, are potent greenhouse gasses (GHGs) that drive climate change. Furthermore, landfills and incinerators are typically cited near low-income communities of color, who disproportionately suffer health effects from these emissions.

We have created an engineered sheet material made from recycled paper and a bioplastic resin derived from agricultural waste. This material addresses the four problems associated with MDF: (1) Production requires zero virgin trees or other raw materials. (2) There is no toxic vapor off-gassing. (3) Structural properties are similar to MDF, yet it is tougher and can be machined without releasing dust particles and can be drilled or screwed into without splitting. (4) It is 100% biodegradable and compostable in natural environments.

Our solution serves four target populations: (1) Workers who manufacture MDF and its products. These workers are often exposed to toxic and carcinogenic chemicals in the course of their work. Our solution avoids such exposure. (2) Every occupant of housing where MDF has been used as a construction material. MDF can off-gas toxic chemicals for up to many years. Our solution has no toxic vapors and thus eliminates the associated risks of eye and lung irritation and cancer. (3) Low-income communities of color who live and work near landfills or incinerators. These communities disproportionately suffer health effects from toxic landfill and incinerator emissions. Since our solution is 100% biodegradable in natural environments, it can be composted rather than disposed of in a landfill or incinerator, thus avoiding associated toxic emissions. (4) Future generations. MDF must be disposed of in a landfill or incinerator, which emits potent GHGs and poses climate change-related risks to future generations. Our solution can be composted in natural environments, thus avoiding GHG emissions.

Many of our family members are wood workers, carpenters, and contractors who have worked with MDF. All of our team members have used MDF products (e.g., furniture) and have been exposed to toxic chemicals as a result of MDF off-gassing in our places of residence and work. We employ the “design thinking” process to ensure meaningful community involvement. We have interviewed and observed the end users of our product to uncover their needs, and we have solicited their feedback regarding our prototypes to help us iterate and refine the solution.

A primary reason we are applying is to raise funds. We have created an initial prototype but we need funding to conduct further testing and to obtain various certifications related to material properties and performance. We will also require additional funding once we are ready to pilot, grow, and scale the solution. Another reason we are applying is to get help forging connections with relevant stakeholders who have the knowledge and power to help us implement and scale our solution.

Adoption of stringent formaldehyde emission regulations in many countries is expected to hinder MDF market growth despite increasing demand. Our solution has no toxic emissions, and we aim to offer a product comparable in price to MDF, which will position us to meet this projected market demand.

Measurable indicators of impact include:

• MDF market penetration

• Reduction in GHG emissions

• Reduction in material footprint (particularly wood)

• Tons of paper recycled

• Reduction in the number of deaths and illnesses from hazardous chemicals and air, water and soil pollution and contamination

We have created an engineered sheet material made from recycled paper and a bioplastic resin derived from agricultural waste. The paper is recycled using industry-standard methods but without the de-inking step, which uses toxic chemicals and significant water, as this process is unnecessary for our solution. The bioplastic resin is derived from agricultural waste rather than virgin (and often GMO) food crops, as is commonly done with other bioplastics.

We have created several physical prototypes and have conducted material testing to determine physical, structural, and functional properties.

Our product is a direct replacement for MDF, which is already widely used in housing and furniture construction around the globe. We will sell our material to individual consumers (wood workers, contractors) and companies (housing construction, furniture manufacturers). The global MDF market reached a value of $25.12 Billion USD in 2020. It is projected to exhibit a compound annual growth rate (CAGR) of 3.5% to 5.6% during the period of 2022-2027.

We will achieve financial sustainability by selling our material to individual consumers and companies.