Cast Carbon, a pioneering startup focused on revolutionizing building materials with environmental sustainability, has successfully secured grants from the New York State Energy Research and Development Authority (NYSERDA) and the National Science Foundation (NSF) for a Phase 1 demonstration of its groundbreaking material. These grants are a significant milestone in Cast Carbon’s journey to bring its innovative, eco-friendly building materials to market, helping to address the global need for sustainable construction solutions.
Cast Carbon’s innovative material, a type of “botanical cement”, marks a significant leap forward in sustainable building practices. By using minerals to bind plant matter into a solid form, Cast Carbon merges the strengths of both the plant and mineral worlds. The result is a renewable, lightweight material that sequesters carbon while offering the durability, fire resistance, and stability of traditional mineral-based products
Cast Carbon’s decision to pursue both federal and state funding underscores its commitment to tackling the significant environmental challenges posed by the built environment. With nearly 50% of the world’s solid landfill waste, potable water contamination, and carbon emissions linked to construction and building materials, innovations must pave the way for a more harmonious relationship with nature.
“These grants are crucial for Cast Carbon, especially as a pre-revenue startup in the sensitive research and development phase,” said Emily Majewski, Co-Founder of Cast Carbon. “Securing government funding is essential for de-risking material innovation, which typically struggles to attract private investment until it’s more mature. Public investment plays a significant role in driving technological advancements, a fact that’s often overlooked when discussing the origins of modern innovations. The development of the smartphone, largely funded by federal agencies like DARPA, is a prime example of how government support is critical in bringing transformative technologies to market.”
Currently, the company is developing this material into tiles that not only store carbon, but also improve a building’s insulation, acoustic buffering, and passive fire resistance. Cast Carbon’s mission goes beyond product development; the company is dedicated to revitalizing the rural economy through the cultivation of plant-based components and supporting urban renewal by providing a carbon-smart solution to the challenges of aging infrastructure.
The Phase 1 demonstration was conducted at the historic Tri-Main Center in Buffalo, NY. Originally a Ford Model T factory and later a hub for top-secret jet engine developments during World War II, the Tri-Main Center was revitalized into a community of over 120 diverse businesses and organizations. The building’s rich history deeply rooted in innovation, combined with its contemporary vibrancy, provided an inspiring environment for Cast Carbon’s work.
“Cast Carbon’s co-founders, both proud Buffalo natives, have a deep connection to the city and its unique blend of history, resilience, and community spirit,” said Susan Fernandez, Co-Founder of Cast Carbon. “Buffalo’s industrial past, ongoing revitalization, and reputation as a city of good neighbors have profoundly shaped our company’s vision and values. We are incredibly grateful to the Buffalo-based organizations that have supported us along the way, including Eco Logic Studio, Cazenovia Recovery Systems, and WEDI, which provided a critical bridge loan that helped us establish our operations here. Their collective efforts have been instrumental in bringing our demonstrations to life and showcasing the potential of Cast Carbon’s sustainable building materials.”
With the successful completion of Phase 1, Cast Carbon is now preparing for the next steps in its journey. The company, headquartered in Buffalo, has partnered with a manufacturer in Brooklyn, NY, and plans to expand production this fall. Additionally, Cast Carbon is working to support the growth of bio-commodity production throughout New York State, aiming to foster a robust supply chain for industrial hemp and biochar in the future.
