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A D V A N C E D M A T E R I A L S & P R O C E S S E S | F E B R U A R Y / M A R C H 2 0 2 0 9 PROCESS TECHNOLOGY BACTERIA STRENGTHENS NEW BUILDING MATERIALS Researchers at the University of Colorado Boulder, are using bacteria to develop building materials that not only live and multiply but may also de- liver a lower carbon footprint. This new approach to design more sustainable buildings could save on emissions and cost. While large-scale production of the microorganisms isn’t feasible yet, researchers say their ability to keep the bacteria alive with a high success rate shows the materials’ promise for mul- tifaceted use in the future. Using these materials could lead to self-healing structures that absorb dangerous tox- ins from the air or glow on command. Manufacturing cement and con- crete for today’s roads, bridges, sky- scrapers, and other structures gener- ates nearly 6% of the world’s annual emissions of carbon dioxide. The new materials could mitigate this. The UC Boulder researchers ex- perimented with cyanobacteria. These green microbes absorb carbon dioxide gas to help them grow and make calci- um carbonate—the main ingredient in limestone and cement. The manufacturing process in- volves inoculating colonies of cyano- bacteria into a solution of sand and gel- atin. The calcium carbonate churned out by the microbes mineralize the gel- atin, which binds together the sand and produces a brick. The bricks are comparable in strength to today’s construction mortar and could potentially remove carbon dioxide from the air. The researchers also discovered how to make their ma- terial reproduce. When cut in half, each piece can grow into a new brick. The discovery has foundational implications for successfully construct- ing microbial structures in the future. colorado.edu . PENN STATE IMPROVES METAL CASTING PROCESSES As part of the Pennsylvania Man- ufacturing Initiative, engineers at Penn State, University Park, are working with small-to-medium-sized found- ries across the state to reduce costs through 3D printing as well as aid in the transition away from using harmful silica sands in the metal casting process. The initiative is part of a state- wide push to drive new technolo- gies and processes in the manufac- turing sector. Metal casting is a $33 bil- lion industry that provides near- ly 200,000 American workers with jobs, according to the American Found- ry Society. Due to new regulations from the Occupational Safety and Health Administration, foundries must begin to switch from silica sands to ceramic sands. Inhaling the fine particles of sil- ica sand can lead to a type of lung dis- ease caused silicosis. Ceramic sands are reportedly saf- er due to their spherical shape and rig- orous testing to ensure uniform grain, chemistry, and physical properties. The first grant will send Penn State students and their research supervisors to work with foundries across the state on the deployment of non-silica aggre- gates in metal casting. Additionally, fac- ulty members will provide webinars for Pennsylvania foundry leadership on im- plementation strategies and conduct training workshops in conjunction with the Pennsylvania Foundry Association. The Penn State projects could help keep the doors open for Pennsylvania’s small-to-medium-sized foundries that otherwise may have to shut down when they can’t keep up with the changes. psu.edu . A sculpted piece made from living build- ing materials. Courtesy of UC Boulder College of Engineering & Applied Science. BRIEF Premier Forge Group, Rosemont, Ill., a portfolio company of Wynnchurch Capital LLC, has acquired California Am- forge Corp., Azusa, Calif., a leading manufacturer of closed die, upset, and rolled ring forgings for the aerospace and defense as well as oil and gas industries. wynnchurch.com. This research team is helping to improve Pennsyl- vania’s foundries. Courtesy of Robert Voigt .