Wooltex

Design Led Material R&D

2023-24

Research Internship

An exploration of strong wool and natural rubber for biomaterial development and design.

Design Criteria

Biocompatibility

The material composition must be derived from natural ingredients.
The composite should be capable of decomposing in a domestic compost heap, ensuring minimal environmental impact
Wool Integration

The material should predominantly feature wool to support the wool industry and leverage its inherent qualities.
Seek to enhance and complement the natural characteristics of wool through the combination with latex.
Material Qualities

Maintain and amplify the inherent properties of both latex and wool.
The whole is greater than the sum of its parts
Process

Optimize the manufacturing process for efficiency and sustainability.
Minimize energy consumption during production.

Context

This project was part of a wider industry push to develop materials that utilise strong wool in New Zealand. The internship was created through a partnership between Massey University and Agresearch. It aimed to see how a design-led approach to material development might bring fresh perspectives to a field dominated by material scientists and Chemists.

I was responsible for designing both the process and the final outcome, utilizing aspects of transition design and material-driven design frameworks alongside traditional industrial design methodologies. Throughout the project, I had weekly check-ins with my two supervisors, Peter Brorens, a material scientist, and Faith Kane, a textile designer. At the conclusion of the project, I presented the project to the wider company.

Material Experiments

Chopped Wool

Heat pressed chopped wool with latex.
Heat Pressing

Different molds and settings on a heat press.
Layering

Experiments layering felted wool and latex.
Chopped Wool

Adjusting wool particle sizes and latex ratios in heat press.
Dying

Adding Natural dyes to latex.
Mechanics

Adding the mechanics of the latex back through folds and material layout.
Latex Foams

Experimenting with latex foams.
Foam + Misc

Variations of foamed latex and miscellaneous additives.
Foam Additives

Adding additional powdered substances to foam to change its properties.
Foam Densities

Changing the wool to latex ratio to effect the density of the foam.

Final Material

The resulting material is a latex foam with a tough exterior skin. It has similar cushioning as traditional foams and a natural appearance with the fibers from the wool visible on the surface. The wool provides tear resistance, surface durability, and breathability. The addition of wool also means less latex is required for the same volume of foam.

Surface Application

There is potential to apply the foam directly to objects or surfaces creating a soft layer that feels and looks like wool. This could also be used to mend damaged surfaces on existing products, bringing a new look to worn surfaces and extending the products life cycle. Different colours and densities can also be applied to create variation and customisation.

Design Proposal

I explored a range of potential products and used product development as a tool to critically drive the material design. Foam has many uses and appears in many different products. It was important not to reduce the material to one product.