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

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.