Material and technological recombinations for low-cost construction elements

Composites with coconut fiber and flexible devices with 3D printing

Abstract

This study addresses the integration of natural materials and digital fabrication to create sustainable construction elements. In Salvador (BA), challenges such as housing deficits, inefficient waste disposal, and limited access to technology motivated the search for low-cost, low-impact solutions. The research was conducted using a “research by design” approach, which involved a literature review, the development of homemade equipment, the use of 3D printing, and the production of prototypes. The focus was on using coconut fiber — an abundant urban waste — combined with gypsum and resin, molded using PLA-printed devices. Coconut fiber proved to be an effective aggregate, especially in composites with gypsum, showing promising acoustic and mechanical performance. Flexible molds and devices were developed on a small scale, enabling the production of modular acoustic pieces. Prototypes are being tested for sound absorption and mechanical resistance, with prospects for practical application and replicability. The research highlighted the potential of combining high and low technologies to foster social innovation. The use of local waste materials and accessible technologies enables sustainable construction solutions, with applications in education, outreach, and habitat improvement.