Prime Flex

What is it?

A versatile composite material that blends biochar sourced from waste biomass (wood waste left over from industrial processing) with bio-based polyolefins. The biochar consists mostly of sequestered carbon which is captured within the material. This results in a lower GWP (Global Warming Potential) from cradle to gate, according to an independently audited LCA, thus outperforming fossil polymers and even other bio-based plastic alternatives on emissions balance. It was developed specifically for injection moulding applications and is commercially available in granulate form.

Material properties

  • Tensile Modulus (ISO 527, MPa): 1623

  • Yield Strength (ISO 527, MPa): 25,3

  • Yield strain (ISO 527, %): 4,4

  • Flexural Strength (ISO 178, MPa): 35

  • Flexural Modulus (ISO 178, MPa): 1770

  • Charpy Notched Impact Strength, +23°C (kJ/m2): 6,07

  • Density (kg/m³): 1,09

  • Melt Volume-Flow Rate (cm3/10min): 3,09

Positive Plastics_Made of Air

Technical benefits

Prime Flex has good UV stability, stiffness, and thermal resistance.
The biochar is a compatible filler for compounding with various polymer types. Recent studies on such compounding mention improvements in thermal, electrical, and mechanical properties.

Look and feel

Available in black only because of the biochar content. It has a fine, almost ceramic-like feel. Its look can result in a range of finishes depending on the surface of the tools used in manufacturing.

Environmental benefits

Regional forestry industries provide the company with raw material in the form of wood waste left over from industrial processing. This wood waste would otherwise be incinerated to generate energy, or landfilled or left behind to decompose – all of which re-release the carbon originally sequestered in biomass back into the atmosphere. 

By converting this biomass into biochar, a form of pyrolyzed biomass with a high carbon content, the re-release of CO2 is prevented. The CO2 sequestered from the atmosphere becomes permanently locked in the biochar, which is later combined with biopolymers to create carbon-negative thermoplastic compounds.

Applications

Suitable for injection moulding and extrusion, ideally in medium- to thick-walled parts of at least 1mm. Possible applications include built environment products, automotive parts, furniture, appliances, and other consumer goods.

chairicon.png
Tray.png
consumergoods.png

Why we chose this material 

There are already many bio-based polymers on the market, but very few use biochar as a filler material. Because it’s sourced from industrial waste, we see a double benefit in this material.

Why you should consider this material

  • You are looking for a naturally coloured black polymer.

  • You are looking for a bio-based polymer using secondary (waste) resources.

About the manufacturer

Founded in 2016, Made of Air produces carbon-negative thermoplastic compounds that can be used in a wide range of applications in which durability and long lifetime are required. Made of Air has already partnered with large consumer brands to deliver carbon-negative materials to their supply chains.