Waste to Paste: Sustainable and Circular Novel Material Composites for Explorative Prototyping in Product Design Practice

Mazabow, Saul

Waste to Paste: Sustainable and Circular Novel Material Composites for Explorative Prototyping in Product Design Practice

Mazabow, Saul

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Publication Type:: Thesis
Issue Date:: 2025

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Field	Value	Language
dc.contributor.author	Mazabow, Saul
dc.date.accessioned	2025-06-04T05:04:22Z
dc.date.available	2025-06-04T05:04:22Z
dc.date.issued	2025
dc.identifier.uri	http://hdl.handle.net/10453/187616
dc.description	University of Technology Sydney. Faculty of Design, Architecture and Building.	en_US.UTF-8
dc.description.abstract	This research focused on developing sustainable product design practices concerning exploratory prototyping. Exploratory prototypes, used to evaluate aspects of a design such as form and function, are typically made from non-recyclable materials such as polyurethane and thermoplastics, and finish their short lives in landfills. This research contributes to ongoing experimental work focussed on developing novel material composites (NMCs) as a sustainable alternative to thermoplastics. This research aimed to develop and test a biodegradable prototyping material consisting of locally sourced, non-toxic industry waste and cellulose derivatives combined with a low-cost material extrusion (MEX) paste 3D printing system. Conducted through product design practice using a research through design (RtD) approach, the research process was documented through a series of contextual portfolios (CPs). These portfolios captured the development of a 3D printable paste using brewer’s spent grain (BSG) as a functional filler in a cellulose-based NMC. This paste and an open-source extruder and pneumatic paste delivery system aimed to reduce thermoplastic use. The BSG-NMC paste and 3D printing system were refined and tested by printing prototypes like computer mice and gaming controllers. The resulting artefacts demonstrated the paste's effectiveness and durability, making it a viable, eco-friendly alternative to traditional thermoplastics in exploratory prototyping.	en_US.UTF-8
dc.format	Thesis (PhD)
dc.language.iso	en_US	en_US.UTF-8
dc.relation	https://opus.lib.uts.edu.au/bitstream/10453/187616/1/thesis.pdf
dc.rights	info:eu-repo/semantics/openAccess
dc.rights	The author owns the copyright in this thesis including all reproduction and reuse rights for the work. The work may not be altered without the permission of the copyright owner. Attribution is essential when quoting or paraphrasing from this thesis.
dc.rights	© 2025 Saul Mazabow
dc.rights	au.edu.uts.lib/cph
dc.title	Waste to Paste: Sustainable and Circular Novel Material Composites for Explorative Prototyping in Product Design Practice	en_US.UTF-8
dc.type	Thesis
utslib.copyright.status	open_access	*

Abstract:

This research focused on developing sustainable product design practices concerning exploratory prototyping. Exploratory prototypes, used to evaluate aspects of a design such as form and function, are typically made from non-recyclable materials such as polyurethane and thermoplastics, and finish their short lives in landfills. This research contributes to ongoing experimental work focussed on developing novel material composites (NMCs) as a sustainable alternative to thermoplastics. This research aimed to develop and test a biodegradable prototyping material consisting of locally sourced, non-toxic industry waste and cellulose derivatives combined with a low-cost material extrusion (MEX) paste 3D printing system. Conducted through product design practice using a research through design (RtD) approach, the research process was documented through a series of contextual portfolios (CPs). These portfolios captured the development of a 3D printable paste using brewer’s spent grain (BSG) as a functional filler in a cellulose-based NMC. This paste and an open-source extruder and pneumatic paste delivery system aimed to reduce thermoplastic use. The BSG-NMC paste and 3D printing system were refined and tested by printing prototypes like computer mice and gaming controllers. The resulting artefacts demonstrated the paste's effectiveness and durability, making it a viable, eco-friendly alternative to traditional thermoplastics in exploratory prototyping.

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http://hdl.handle.net/10453/187616