Crystallized: Towards Resinless Fabrication of Complex Nonlinear Spatial Forms Using Fiber-Reinforced Crystal Composites (FRCCs) and Coreless Filament Winding (CFW) Techniques

Abstract

Petroleum-based resins used in fiber-reinforced composites (FRCs) offer high performance but carry a substantial environmental burden. This study investigates crystallized composites (CCs) as a resinless alternative capable of binding loose cotton reinforcement within a crystalline matrix while providing a distinct material expression. Because crystallization in construction research has largely been documented in relation to salt transport, corrosion, and crystal growth, the potential of crystal-based matrices as composite binders remains underexplored. An abductive, proof-of-concept methodology was used to screen matrix-reinforcement combinations and fabrication parameters. Six salt-based matrices and several reinforcement systems were evaluated, followed by a manual adaptation of coreless filament winding (CFW) principles to fabricate a full-scale stool demonstrator. The demonstrator was subjected to a single quasi-static seated-load demonstration with a seated person with a body mass of approximately 80 kg, without visible failure during the observation period. This observation demonstrates fabrication feasibility and short-term functional integrity, but it is not a substitute for standardized mechanical characterization. The alum-based system could also be dissolved in hot water and recrystallized, indicating recoverability of the alum phase through dissolution and subsequent recrystallization. The findings establish the feasibility and novelty of a resinless fiber-reinforced crystal composite concept while identifying mechanical characterization, moisture resistance, durability, process energy, and environmental assessment as necessary next research stages.

The authors' abstract, as published at the source. Buildings, 2026 · DOI ↗