Denimite

Solid surfacing made of recycled denim scraps combined with a partial bio-based thermoset resin binder under high pressure and heat. The panels resemble a Sodalite Gemstone (royal blue mineral), are moldable and lightweight, with no off gassing as the resin does not contain VOCs. The material is pressed in sheets ready for secondary processing (cutting, gluing, sanding) or pressed into custom molds. Because the fibers are not woven (like carbon fiber), but intertwined randomly, the material has strength in all directions. The recycled denim fibers are a mix of long and short, coarse and fine fibers, as well as threads and intact pieces of woven textile material. This aids in the ‘mold-ability’ of the material, and gives it a unique random visual texture. It can be fabricated and cut with standard woodworking tools, and sanded or buffed to the desired finish. By varying the amount of pressure in the press, the manufacturer can specify the density and strength characteristics throughout a custom part. The material is impervious to water with no sealing required. The material is available in panels that are 30 x 120 in (0.76 x 3 m) in size with ½, ¾ and 1 in (12.7, 19.05 and 25.4 mm) standard thicknesses. Each panel is unique due to the recycled content, there may be threads of other colors, but the material will have an overall blue tone. Colored pigments may be added to the resin. Sheet size, thickness, pigments and molding shape can be customized. Applications include countertops, walls, furniture and consumer goods.