From Mud and Straw to High-Tech Materials: The Rise of Biocomposites
When early Egyptian and Mesopotamian settlers mixed mud and straw to construct their buildings, they likely didn’t anticipate that this simple technique would last for over 3,500 years. Yet, this ancient method of combining natural fibers with a binding material is the precursor to today’s innovative and rapidly growing biocomposite industry—a sector transforming multiple industries, from automotive to aerospace.
What Are Biocomposites?
At its core, a composite material is made from two key components:
A matrix (or binder) that holds the structure together and distributes loads.
Reinforcing fibers, which provide strength and stiffness, either woven or non-woven.
Traditionally, these components were synthetic and non-renewable—think petroleum-based resins combined with glass or carbon fibers. Biocomposites, on the other hand, replace one or both of these elements with bio-based materials.
Most commonly, biocomposites use natural fibers such as flax, hemp, jute, kenaf, or wood. These are often called natural fiber reinforced plastics (NRPs). While natural fibers are well-established, creating a fully bio-based matrix remains technically challenging. Plant oils—from hemp, linseed, or castor—are being explored to produce bioresins, but achieving the mechanical and thermal performance required for industrial applications often still requires blending with synthetic components.
The Modern Biocomposite Revolution
Companies like SHD Composites are pioneering the integration of UK-grown hemp and flax into high-performance resin systems. By switching from imported fibers to local supply chains, SHD is reducing environmental impacts while maintaining the quality needed for demanding applications in automotive, aerospace, and other advanced industries.
A typical modern biocomposite manufacturing process involves creating a hybrid-interlayer composite:
Dissolving a bio-based epoxy in a solvent to form a resin solution.
Impregnating recycled carbon fiber mats and reinforcement fabrics with the resin, creating prepregs.
Layering these prepregs into a sandwich structure.
Compression molding the structure to produce the final composite panel.
This approach demonstrates the versatility and performance potential of biocomposites, combining sustainability with industrial-grade functionality.
Moving Toward 100% Bio-Based Materials
Today, most commercial bioresins are only partially bio-derived, often containing up to 30% bio-content. This reduces reliance on petrochemicals but does not fully meet sustainability goals.
However, innovators are pushing the boundaries:
BitRez is developing fully bio-derived thermosetting resins for automotive and aerospace applications.
Vitality Acoustics is exploring 100% bioresins for acoustic panels, merging sustainability with sound performance.
Scott Bader, an employee-owned UK manufacturer, has created Crestafire® Bio P1-8001, a 100% bio-based resin from sugarcane waste. This material achieves the highest fire performance rating in Europe and offers moisture, mold, and pest resistance—opening doors for use in safety-critical environments like transport and construction.
The Future of Biocomposites
From humble beginnings in ancient civilizations to the high-tech applications of today, biocomposites are redefining what’s possible with sustainable materials. Advances in bioresin technology and natural fiber integration are creating truly circular, renewable composites—materials that eliminate fossil-based content without compromising performance.
As industries continue to prioritize sustainability, biocomposites are poised to become a cornerstone of a greener, stronger, and safer future.
