The Development of Our Carbon Fiber Alternative
Melanyte™ is our patented structural material inspired by the composition of a Toucan’s beak - a dense outer shell overlaying a rigid foam making a strong yet lightweight structure. These components are cured together, creating a strong interlocking bond between the inner and outer layers. This gives the final product tremendous compressive strength while retaining a degree of malleability.
Why Melanyte™ is Superior to Carbon Fiber
Carbon fiber composites are strong, but their mechanical properties are dependent on the direction of the fibers. To fix this, more layers of material are added, all aligned differently, adding significant cost and weight as well. Our patented technique for Melanyte™ allows us to make a structure that is stronger in more directions with a safer and less catastrophic mode of failure.
The process of making Melanyte™ is also far less energy-intensive than carbon fiber, needing only raw materials and a mold able to withstand a moderate amount of pressure. Melanyte™ can be cured at room temperature in eight hours, permitting the inclusion of heat-sensitive fuel lines or wires. The curing process can also be accelerated by applying a low amount of heat to the mold, with temperatures and timelines still less than carbon fiber composites.
The Benefits of Melanyte™
We are very proud that Melanyte™ is Colorado-made with non-foreign materials. This helps us maintain control, solidifying lower costs and a reliable supply chain. While we are still expanding our knowledge on the limitations of our process, we have successfully made rods, beams, panels, wings, and curved surfaces. These serve as the structural foundation to our agricultural rover and wind-powered water generator.
