BE OPEN BLOG

From Seoul to Mexico City to Norfolk, these projects reveal a powerful trend in contemporary design: the blending of traditional materials, biological waste, and next-generation technologies to create radically sustainable building solutions. Eggshells – humble, fragile, and ubiquitous – are no longer seen as the end of a life cycle but the beginning of a new one. Because sometimes, to build the future, you just have to break a few eggs.

In South Korea, where construction waste comprises nearly half of the country’s total waste, a team of designers at Seoul National University’s Living Design Lab is reimagining how buildings are made – and unmade. Their project, Re:shell, transforms discarded eggshells into modular, biodegradable building bricks, designed to seamlessly reintegrate into nature at the end of their lifecycle. These interlocking brick-like units serve as a zero-waste alternative to conventional construction materials, offering versatility for everything from architectural facades to small-scale design products.

This innovative material was born from a growing national concern: how to manage the debris from South Korea’s rapid industrial expansion in the late 20th century. As older buildings from the 1970s and ’80s face demolition, the resulting waste poses a significant environmental challenge. In response, the design team fused traditional Korean architectural values – like adaptability and harmony with nature – with modern material science, leveraging the natural strength of eggshells as a key ingredient. Their aim: to create a building material that not only minimizes harm but actively benefits the ecosystem.

At the heart of Re:shell is calcium carbonate (CaCO2), the main component of eggshells and a natural binding agent also found in cement. After collecting waste shells from local bakeries and restaurants, the team processes them into a fine powder and blends them with natural additives such as red clay, wheat bran, and straw. These ingredients enhance the bricks’ texture, durability, and flexibility while maintaining full biodegradability. In soil decomposition tests, Re:shell showed promising results – crumbling naturally without leaving toxic residue.

Looking ahead, the team is refining the composite to be waterproof without compromising its environmental integrity. Drawing inspiration from traditional Korean design elements like the soban table and multifunctional interiors, Re:shell’s modular system represents a vision for future construction: one that is scalable, sustainable, and rooted in cultural identity.

Continuing the thread, our journey now takes us to Mexico, where cutting-edge robotics meets eco-conscious material science. At the heart of this fusion is The Eggshell Project (Un Proyecto de Huevo), an ambitious initiative by the Mexico-based design studio MANUFACTURA. This research-driven endeavor transforms used eggshells into a sustainable bioceramic, produced through robotic 3D printing – proving that the future of construction might be equal parts nature, code, and cracked shells.

While the ceramics industry is traditionally known for its heavy environmental toll – requiring energy-intensive firing, raw material extraction, and significant emissions – MANUFACTURA’s approach aims to rewrite the narrative. By sourcing discarded eggshells from local food waste streams and pairing them with eco-friendly binders and sustainable aggregates, the team has eliminated the need for kiln firing entirely.

The real magic happens through the use of a KUKA KR-150 robotic arm, which enables high-precision 3D printing of complex geometries. The system’s additive manufacturing process allows for tailored architectural components with minimal waste and maximum design flexibility. From curved building blocks to intricate surface textures, the potential applications span structural elements, facade systems, and beyond.

Completing our trio of egg-powered innovation is a promising research project from the UK, where Master of Architecture student Sam Joy is experimenting with an unexpected duo: typha (a reed plant also known as cattail) and eggshell waste. Developed at Norwich University of the Arts, the prototype investigates sustainable construction through composite bricks made from typha fibres and waste calcium carbonate sourced from both eggshells and mussel shells – two materials commonly discarded in the UK.

This project stands out not just for its upcycling ambition, but for its deeply local and ecological lens. By focusing on reed cultivation through paludiculture – the agricultural use of wet peatlands – Joy’s work supports carbon sequestration, flood control, and habitat restoration, while harvesting a naturally abundant fibre. Paired with upcycled calcium carbonate, the result is a composite material that challenges the high-impact processes of conventional construction.

Crucially, the material choices aren’t just environmentally sound – they’re regionally relevant. By sourcing ingredients from Norfolk’s own landscape and food systems, the project cuts down on transport emissions and lays the groundwork for a circular economy model rooted in place. Still in the experimental stage, Joy’s brick prototype is undergoing testing to assess its strength, durability, and real-world applications. Yet even at this early phase, it reflects a broader design ethos gaining momentum: one where material sourcing, ecological stewardship, and architectural innovation are inseparable.