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In Mohini Sain's vision of the future, the world is free of breakers' yards, rusty vehicles suffering from Canada's salty winter roads and broken car parts clogging landfill sites.

"Most vehicle parts will be 100 per cent manufactured from biomaterials," says Sain, a professor in the University of Toronto's Faculty of Forestry and the Department of Applied Chemistry and Chemical Engineering. "At the end of their cycle, people will be able to cover their cars with soil – right in their back yards – let them biodegrade and eventually plant something over the top."

That's not as far-fetched as it sounds. Working with funding from AUTO21 and industry partners, Sain and his team have successfully manufactured a lightweight, biodegradable material that is currently being tested for use as interior door panels for cars. For the average North American market, such a panel would have a lifespan of 10 to 15 years. Aesthetically and metaphorically speaking, the product still needs some polish to be considered for exterior vehicle parts. It has a certain texture that can't beat the dazzling sheen and smoothness of metal. That aspect is currently being improved.

One of Sain's objectives in developing this product was to be cost-competitive over existing materials. To do that, the team looked at the price of producing plastics for vehicles and used that as a base.

"Right now," says Sain, "we are cost-competitive globally but you have to take other factors into account, such as supply from China. So we're always working on bringing the cost down."

One of the ways to do that is to use a cheap, renewable resource with good performance. Sain's team tried fibres from all over the world before settling on wheat, hemp and wood fibre. Then they worked on developing a cost-effective manufacturing process. The savings here were twofold: in the process itself and in the reduced need for petroleum-based products.

"Biofibres only need half the energy needed to make fibreglass, so that's a saving," explains Sain. "Using natural fibres instead of petrochemical-based fibreglass and synthetic plastics is another saving. Plus, this biofibre is biodegradable so no petro-based energy is spent to recycle it."

The environment is also a winner. Less petro-energy spent in production and a physically lighter, less petro-hungry vehicle mean fewer greenhouse gases released into the air. And because the product breaks down faster than a synthetic, there are fewer problems with waste disposal.

Sain and his team have several U.S. and Canadian patent applications pending and more than seven disclosures in the technologies involved. The work resulted in a spin-off company, Greencore Composites Inc., that is commercializing products for structural applications.

From plant to product
Sain and his team isolated individual fibres from agricultural and woody plants, combined them with chemicals and separated the fibres under pressure. The result is a product that looks and feels somewhat like fibreglass, has the strength of carbon fibre and is just as light. If the fibres are combined with natural polymers, the result is totally biodegradable.

Sain describes the two technologies involved. "The first one involves isolating the fibre in its elemental form and separating it. The second is incorporating it into a plastic and exploding its performance."

Although initial studies used hemp and wood fibres, any plant with strong fibres and good structural integrity is a potential source. The team has experimented successfully with wheat, flax, corn and soya, and is now working with wild carrot roots.

From vehicles to… ???
Says Sain, "The product passed the stringent strength and safety requirements of the auto industry. Now other industries that are in the market for high-performance structural materials can adapt it for their own use."

Other uses in the transport sector include railway crossties and airplane wings. The entire construction industry beckons – from beams to siding to roof shingles to fences. Sain foresees that the electronics sector will make computer, TV and cell-phone casings, and circuit boards from it. It could be used for biomedical devices such as cardiac valves and intravenous blood bags. The sporting industry will surely benefit – canoes, skis, skateboards, helmets. And then there are household appliances, furniture, docks … the list goes on.

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