Research Line: Urban Rural Circularity / Seed Call: i4CS April 2024

In the context of the new upcycling centers being developed in Utrecht (2024–2025), this project seizes the opportunity to transform local wood waste into innovative composite materials with broad applicability. Aligning with the Utrecht municipality’s circular economy goals, it contributes to the target of sourcing at least 25% of locally produced products from local wood. By making discarded wood more accessible and valuable for multiple stakeholders, the project strengthens the local economy and promotes sustainable practices.

Objectives and Route to Impact

Collaboration with Foundation Up/Utopia and its network will facilitate the identification of high-volume but low-value wood waste—such as top branches and trims—for upcycling into composite materials suitable for additive manufacturing. Addressing the challenges posed by wood waste variability, the project prioritizes fresh wood for a more stable supply while maintaining an interest in discarded wood-based products for future research.

Innovative material approaches, including the use of thermoplastic proteins from agri-food side streams, will enhance biodegradability and scalability. Additionally, engagement with upcycle businesses and artists as early adopters of technology-supported repair will support the development of value-added applications. Through these efforts, the project aims to establish new pathways for sustainable material use and circular economy solutions in Utrecht.

Methods

To maximize relevance and impact, this project integrates continuous feedback and collaboration from local businesses (MKB), repair cafés, artisans, and other stakeholders. By aligning research with regional needs, the project aims to establish viable circular material flows and deliver value to the local community. Engagement with municipal outreach initiatives and existing infrastructures, such as upcycling center websites and exhibitions, will enhance the visibility of the URWOOD project, fostering impactful research directions and laying the groundwork for future funding opportunities.

This project addresses key challenges related to creativity in upcycling and the role of art in sustainable material reuse through three primary objectives:

1. Material Development – Processing composite materials from discarded wood to create flexible and functional solutions for multiple local stakeholders.
2. Material Characterization – Testing and reporting on the performance of these composites in terms of functionality, sustainability, and experiential qualities.
3. Community Engagement – Involving artists, businesses, and the broader community in co-creating value-added repair practices using upcycled wood materials.

The research explores material processing, technical performance, design integration, and community participation, with a strong focus on scalability, environmental impact, and safety. Key research questions include:

• How can engagement with suppliers, 3D printing companies, upcycle wood businesses, and repair cafés be optimized to support upcycling initiatives?
• What are the optimal processing parameters for high-quality wood-based composites in additive manufacturing?
• How do mechanical and experiential properties of upcycled wood compare to existing composites, and how can local wood species enhance their functional and emotional value?
• What are the design requirements and accessible workflows for integrating wood composites into repair and artistic practices?

By addressing these questions, the project contributes to advancing circular economy strategies, strengthening local collaborations, and shaping future sustainable material innovations.

Deliverables

The URWOOD project aims to develop a sustainable process for transforming local discarded wood—particularly underutilized top and branch wood—into high-quality composite materials. These materials will be designed for use by local businesses, artists, and designers, promoting circularity and community engagement. By integrating additive manufacturing and thermoplastic proteins from agro-food side streams, the project will demonstrate the aesthetic, functional, and sustainable potential of upcycled wood composites. The deliverables are structured around three key objectives:

1. Development and Optimization of Wood Composite Materials
   • Creating and refining composite materials using thermoplastic proteins and advanced additive manufacturing.
   • Evaluating their technical performance (strength, flexibility), sustainability (biodegradability, carbon footprint), and aesthetics (texture, appearance).
   • Deliverable 1: Prototypes of wood composites, technical data on material properties, and an initial sustainability and aesthetic assessment. These results will inform a follow-up funding proposal focused on mechanical and functional performance.
2. Exploration of Creative Making and Repair Processes
   • Investigating applications of wood composites in repair and artistic design to extend the lifecycle of existing products.
   • Demonstrating practical use cases for value-added repair and customization.
   • Deliverable 2: A report on case studies showcasing the application of composites in repair and artistic projects, guiding future research on design integration.
3. Community Engagement and Integration with Municipal Initiatives
   • Organizing workshops, co-creation events, and on-site demonstrations to align materials and processes with community needs.
   • Strengthening networks for future funding and research opportunities.
   • Deliverable 3: A report summarizing interviews and co-creation sessions with stakeholders, alongside a promotional video to enhance project visibility.
   • Deliverable 4: A consolidated final document integrating material development, application potential, and community engagement insights. This document will include a list of potential academic, community, and business partners for a future consortium proposal.

These deliverables will ensure that URWOOD contributes meaningfully to sustainable material innovation, while paving the way for further research and collaboration.

Contribution to cross-EWUU collaboration

This project unites complementary expertise from three institutions—TU/e, WUR, and UU—to address the challenges of upcycling in the Utrecht region. By combining material sciences, engineering, and interdisciplinary research, the collaboration fosters innovative solutions for circular material use.

At TU/e, Dr. Barati contributes expertise in material-driven design, creative making processes (e.g., bio-fabrication, value-added repair), co-creation, and experience prototyping, while Dr. Magrini provides insights into additive manufacturing, materials testing, and characterization. From WUR, Dr. Zhang focuses on mechanical and chemical processing of bio-waste, transforming it into workable powders or pastes for additive manufacturing. At UU, Emma Luitjens brings expertise in biological processes, bioremediation, and the bio-based economy, ensuring stakeholder involvement and a systems perspective on circular design.

This collaboration integrates deep disciplinary knowledge in materials science and engineering (WUR, TU/e-ME) with inter- and transdisciplinary research approaches (UU, TU/e-ID). By engaging communities and co-creating alternative futures, the project leverages insights from chemistry, biology, and engineering to optimize materials for enhanced properties, resource efficiency, and sustainability. The partnership ensures that technical advancements are developed alongside social, experiential, and environmental considerations, strengthening the impact and applicability of upcycled materials.

Team

• Bahareh Barati – TU/e Department of Industrial Design – Principle Investigator
• Lu Zhang – WUR Laboratory of Food Process Engineering
• Emma Luitjens – UU Copernicus Institute of Sustainable Development
• Tommaso Magrini – TU/e Department of Mechanical Engineering