Innovative Synthetic Biology Solutions for Carbon-Negative Manufacturing Alternatives

The shift away from fossil fuels requires a significant transformation in our manufacturing processes. This is crucial since hydrocarbons present in fuels such as crude oil, natural gas, and coal are also found in common products like plastics, clothing, and cosmetics.

Merging Synthetic Biology with Chemical Catalysis

A pioneering company is merging synthetic biology with chemical catalysis to revolutionize production methods while significantly lowering greenhouse gas emissions. By utilizing microbes to ferment biomass waste, including wood chips, this innovative approach creates a valuable molecular building block known as mevalonic acid. This method allows for the sustainable production of a variety of products ranging from automotive tires and cosmetics to aviation fuels, through adjustments in the chemical processes to generate different byproducts.

Expanding Applications and Carbon-Negative Vision

Initially focused on isoprene, a key rubber component derived from mevalonic acid, the company has expanded its platform. This unique blend of chemistry and biology enables rapid and efficient decarbonization across multiple supply chains. Imagine achieving carbon-negative yoga pants; this vision is becoming a reality. From personal care products to industrial applications, this platform is actively promoting sustainability in manufacturing.

“The production process can be carbon-negative, allowing for a reduction—and even reversal—of climate change impacts.”

Founder’s Journey and Technological Advances

The term “carbon-negative” is frequently emphasized, as the company has already established partnerships with major consumers of isoprene. The aim now is to validate this innovative process in industries known for high emissions.

The carbon-negative aspect arises from the fact that plants absorb CO2 from the atmosphere. By processing this plant material into structural products such as synthetic rubber, used in roofing and tires, the captured CO2 remains within the materials even at the end of their lifecycle—either recycled into roads or potentially ending up in landfills. This means the production process can be carbon-negative, allowing for a reduction—and even reversal—of climate change impacts. This insight was developed a decade ago during studies at MIT.

During his doctoral research, the founder examined the economic benefits of using microbes to produce high-octane gas additives while also delving into sustainability and entrepreneurship at MIT Sloan School of Management. This inspired the creation of a company dedicated to addressing the significant climate impact associated with petroleum use—not just as fuel but also as a material source for everyday items.

From Lab Innovation to Market Impact

Through an analysis of advances in synthetic biology and fundamental calculations, it became clear that utilizing microbes to enhance rubber production was feasible. Participation in the MIT Clean Energy Prize helped solidify this concept, leading to further development after graduation while juggling a consulting role and renting lab space to bring sustainable rubber to fruition.

After 18 months of applying engineering principles to synthetic biology, a microbe was developed that met 80% of the necessary criteria for creating mevalonic acid. Subsequently, a chemical catalysis process was established to convert mevalonic acid into isoprene, which is integral to natural rubber production. Further advancements have led to patented processes that enable the conversion of mevalonic acid into aviation fuel, polymers, and fabrics.

Sustainability and Market Expansion

In 2014, the founder transitioned from consulting to focus entirely on the company with support from an incubator that empowers scientists to innovate.

Currently, the company markets not only isoprene but also skin care products under a new brand utilizing mevalonic acid-based creams made from recycled plant byproducts. Offering refillable bottles and emissions offsets for product shipping underscores a commitment to sustainability across the supply chain.

The strategy involved targeting the isoprene segment of the rubber supply chain initially but has since evolved to include healthier alternatives for personal care products that replace petrochemicals with sustainable ingredients. The launch of this brand showcases how synthetic biology can transform carbon-negative materials into high-performance products.

Future Prospects in Aviation Fuel

Additionally, regulatory approval processes are underway for sustainable aviation fuel production, which holds significant potential for climate impact by transforming how fuels for commercial flights are produced.

By working alongside industry leaders, efforts are being made to decarbonize aviation fuel, shifting from traditional methods that extract hydrocarbons and emit CO2 to a model that uses plant matter capturing renewable energy bonds, converting it into aviation fuel and other sustainable products that retain carbon. This operational model promotes net-zero carbon emissions in manufacturing facilities.

With millions in revenue already generated, there are ambitious plans to scale operations rapidly now that the foundational molecule has been validated, aiming for a tenfold increase in technology deployment every two to three years—an exciting prospect for achieving substantial environmental impact.