This is the start of the ecoboard.live documentation. I’m going to be writing up everything I’ve found out during the process of incorporating wheat paste into Cardboard MDF.
Apologies for any missing information or topics, the website is still in early development.
Designing a Mold for Cardboard MDF with Wheat Paste
Overview
- Cardboard Medium Density Fibreboard (MDF) is a cost-effective material used in large-scale applications like construction but remains largely untapped for smaller products.
- Cardboard MDF is rarely used in smaller-scale manufacturing because of the binder, Urea-Formaldehyde which is used in large-scale manufacturing that’s toxic and difficult to work with.
- On a smaller business scale, cardboard MDF is manufactured with environmentally harmful binders such as Polyvinyl Acetate (PVA).
Process Discovery (XYZAiden)
- In 2021, Aiden Leitch discovered that cardboard could be blended with Polyvinyl Acetate (PVA) and pressed in a 3D-printed mold to create any cardboard MDF package or item, of any thickness.
- PVA is environmentally harmful, so Leitch’s research attempted to expand and use rice paste and cornstarch as binders but had negative results as the strength of the MDF was low.
- This process can make Cardboard MDF molding accessible, but there weren’t any known human and environmentally-friendly binders that work for MDF.
Why Wheat Paste
- Wheat paste is made purely from water and flour, combined in a cold/hot mixture.
- In my testing wheat paste was cheaper, environmentally friendly, and just as strong as PVA.
- Overall it’s a better replacement when making Cardboard MDF.
How To Make Wheat Paste?
- Here’s a great video on how to make wheat paste in 2 minutes:
- How to make Wheat Paste in 2 Minutes
- Here’s a quick way to make it:
- Optional: You can also add a small amount of vinegar to prevent mold growth.
Process
- We will be using XYZAiden’s method to press Cardboard MDF molds. Please view his Instructables Page
Design
- Designing 3-Part molds for Cardboard MDF is similar to any other 3-part system.
- There are a few things to note:
- Rounding all sharp corners and adding draft angles stop the inserts from breaking while being removed
- Cooking the cardboard in molds at 150F will dry them quickly without ruining the 3D printed mold (melts at 500F)
- Side Drainage Holes allow the water vapor to release while drying in an oven (Weeping Holes)
- If you would like to see some examples of the molds, please view my GitHub, Thingiverse page, or XYZAiden’s Thingyverse page.