Biopolymer-based flame retardants (FR) are a promising approach to ensure adequate protection against fire while minimizing health and environmental risks. Only a few, however, are suitable for industrial purposes because of their poor flame retardancy, complex synthesis pathway, expensive cleaning procedures, and inappropriate application properties. In the present work, wheat starch was modified using a common phosphate/urea reaction system and tested as flame retardant additive for wood fibers. The results indicate that starch derivatives from phosphate/urea systems can reach fire protection efficiencies similar to those of commercial flame retardants currently used in the wood fiber industry. The functionalization leads to the incorporation of fire protective phosphates (up to 38 wt.%) and nitrogen groups (up to 8.3 wt.%). The lowest levels of burning in fire tests were measured with soluble additives at a phosphate content of 3.5 wt.%. Smoldering effects could be significantly reduced compared to unmodified wood fibers. The industrial processing of a starch-based flame retardant on wood insulating materials exhibits the fundamental applicability of flame retardants. These results demonstrate that starch modified from phosphate/urea-systems is a serious alternative to traditional flame retardants.

Due to their chemical structure, conventional flame retardants are often toxic, barely biodegradable and consequently neither healthy nor environmentally friendly. Their use is therefore increasingly limited by regulations. For this reason, research on innovative flame retardants based on sustainable materials is the main focus of this work. Wheat starch, wheat protein, xylan and tannin were modified with phosphate salts in molten urea. The functionalization leads to the incorporation of phosphates (up to 48 wt.%) and nitrogen (up to 22 wt.%). The derivatives were applied on wood fibers and tested as flame retardants. The results indicate that these modified biopolymers can provide the same flame-retardant performances as commercial compounds currently used in the wood fiber industry. Besides, the flame retardancy smoldering effects may also be reduced compared to unmodified wood fibers depending on the used biopolymer. These results show that different biopolymers modified in phosphate/urea systems are a serious alternative to conventional flame retardants.

The temperature resistance of glued timber, which is crucial for glued wood construction, represents a significant assessment criterion. To gain insights into this aspect, this study utilized methods such as a shear strength test in accordance with EN 302-1:2013-06 under thermal loading (from 20 °C to 200 °C), and Differential Scanning Calorimetry (DSC) to determine the glass transition temperature (Tg). An increase in thermal load resulted in a decrease in shear strength and an increase in wood breakage. A hierarchy of adhesive groups was established based on strength performance and wood failure percentage (WFP) at 200 °C. Thermoset adhesives (MF: Melamine Formaldehyde, PRF: Phenol Resorcinol Formaldehyde) led the ranking, followed by elastomer adhesives (1C-PUR: One-Component Polyurethane, EPI: Emulsion Polymer Isocyanate), with thermoplastic adhesive (PVAc: Polyvinyl Acetate) last. Thermoset adhesives further cured under heat. PUR adhesives exhibited higher strength performance at 150 °C and lower temperatures.

The blue-green pigment xylindein, produced by the soft rot fungus Chlorociboria aeruginascens, is of considerable interest for various applications such as the veneer industry or organic semiconductors. The studies presented were performed in order to understand the fungal growth as well as the pigment production of C. aeruginascens. Therefore, various nutrient compositions were investigated. As a result, observations of the formation of xylindein through C. aeruginascens decoupling from growth were made. In the primary metabolism the uncolored biomass is formed. Various carbohydrates were determined as nutrients for the fungus and as a nitrogen source it was observed that the fungus prefers the complex organic nitrogen source, that being yeast extract. Furthermore, it was discovered that the ratio between carbohydrate and nitrogen sources encourages the switch of the metabolism and therewith the production of the blue-green pigment xylindein.

The sustainable development of products is of great interest to both industry and consumers due to various factors, such as anthropogenic climate change and the scarcity of resources and materials. In response to this, the simul⁺ Living Lab Sustainable Additive Manufacturing in Saxony (SAMSax) has been established as a physical experimental space aimed at improving the sustainability of products. This includes selecting resource-efficient manufacturing processes, using renewable materials, reducing energy consumption during use, and designing for recyclability. The innovative approach of the lab also integrates an open innovation process, involving present and potential stakeholders. Collaborating closely with stakeholders from industry, academia, and government fosters idea generation, provides solution approaches, and enhances acceptance and practical implementation. Methodologically, SAMSax focuses on upcycling organic and inorganic residues as well as by-products from industry and agriculture, reintegrating them as innovative components in industrial production using additive manufacturing (“3D printing”). The Living Lab provides a space for networking and active knowledge transfer through digital technologies, analyses, and collaborative developments, enabling the testing and evaluation of innovations in a real-world environment. Several potential waste materials suitable for additive manufacturing and new products have already been identified. In addition to industrial residues, materials, such as paper and wood dust; industrial by-products, such as sand; and agricultural residues, like harvest residues, are being analyzed, processed, and tested using additive manufacturing in the laboratory. In this way, SAMSax can contribute to an integrated and consistent circular economy. The research aims to demonstrate that the SAMSax Living Lab is a crucial driver of innovation in the field of additive manufacturing. Furthermore, this study contributes by presenting the Living Lab as an application-oriented research environment, focusing on innovative implementation in small- and medium-sized enterprises.