Introduction to Bio-Based Building Materials: A Guide to Smarter, Healthier Construction

Welcome to a new chapter in sustainable construction. At Flora Materials, we believe the materials we build with should support the health of both people and the planet. That’s why we’re focused on replacing harmful, petroleum-based materials with high-performance alternatives made from bio-based sources.

This guide offers a broad introduction to the growing world of bio-based materials with a particular focus on how we’re advancing them through design, research, and real-world application. Whether you’re an architect, contractor, developer, or someone curious about what’s next in construction, here’s what you need to know (and where we’re headed next).

What Are Bio-Based Building Materials?

Put simply, these are materials—such as tiles or flooring—derived from renewable biological sources like plants, algae, fungi, or agricultural byproducts. Instead of relying on fossil fuels and toxic chemicals, these materials tap into systems that already exist in nature. Think of it as designing with the planet, not against it.

At Flora Materials, we’re demonstrating that renewable substances can power high-performing materials that rival, and often outperform, their fossil fuel-based counterparts. From durability and design to carbon reduction, bio-based materials are reshaping what’s possible in the construction of the places we inhabit.

Whether you’re an architect, contractor, or just curious about the future of design, understanding the role of bio-based materials is the first step toward smarter, more sustainable construction.

Why Do Bio-Based Materials Matter and Why Are They the Future?

The construction industry is responsible for nearly 40% of global greenhouse gas emissions. Much of that impact comes from the materials we use every day. Polyvinyl chloride (PVC), concrete, and steel are carbon-intensive to produce and often toxic at every stage, from manufacturing to installation to disposal. Bio-based materials offer a scalable, healthier alternative that can help reverse that trend.

As the imperative grows for climate-friendly solutions, bio-based materials are quickly moving from experimental to essential—improving air quality, reducing harmful toxins, and supporting a more circular materials economy. At Flora Materials, we believe the future of construction is regenerative, and it starts with what we’re building with.

How Is Flora Materials Advancing Research into Bio-Based Materials?

Our story began in 2020 with a research project at the University of Utah, exploring how algae-based composites could replace the petroleum-derived ingredients commonly found in building materials. That early work laid the foundation for Flora Materials and sparked our mission to prove that bio-based solutions can meet the performance demands of modern materials.

Today, we’re advancing that mission through our partnership with the U.S. Army’s SBIR Program, which supports small businesses to advance Army research and development. With their support, Flora is developing a flooring tile made from bio-based polyurethane composites designed to meet military-grade performance standards.

This means creating products that are not only sustainable but rigorously tested for durability, resilience, and usability across different building types and climate zones. We are working closely with engineers, material scientists, and architects to create a U.S.-sourced, high-performance tile that’s durable, easy to install, and made with 90% or more bio-based content. Our goal is to design products with significantly lower carbon emissions while maintaining the durability, aesthetics, and performance of traditional flooring products.

What Materials Are We Building With?

At Flora Materials, we’re rethinking what building materials are made of. Every part of our tile—from the filler to the resin—is being re-engineered with sustainability and circularity in mind.

To strengthen the tile, enhance texture, and improve overall performance, we’re testing a range of natural fillers that are both functional and environmentally responsible. We focus on materials that are locally available, renewable, or sourced as byproducts from other industries, like cellulose from paper and pulp production or corn grit from agricultural processing. By working with these kinds of inputs, we reduce waste, avoid over-farming, and improve the overall environmental footprint of the product.

Choosing the right filler combinations helps increase the tile’s bio-based content while reinforcing its structure and improving thermal stability. It also allows us to reduce the amount of resin needed, which lowers production costs and minimizes the product’s overall environmental footprint.

We’re also rethinking the resin itself. Instead of relying on petroleum-based polymers, we’re actively testing bio-based alternatives that align with our performance standards and sustainability goals. One of the most promising candidates is a bio-based monomer derived from tulip plants, which has shown strong results in both UV and thermal curing systems. Innovations like this help us replace fossil fuel-based ingredients without compromising durability, versatility, or ease of installation.

While our initial focus is flooring, the material platform we’re developing has far broader potential. We’re exploring algae-based composites for use in wall panels, ceiling tiles, acoustic insulation, and exterior cladding. As we continue to refine our technology, we’re laying the groundwork for a new category of high-performance, bio-based building materials.

What’s the Hidden Cost of PVC and Why Should We Replace It?

PVC (polyvinyl chloride) remains one of the most common materials in flooring—and one of the most problematic. It’s estimated that the production of PVC used in traditional flooring materials contributes upwards of 10 million tons of CO₂ annually.

The environmental impact goes beyond emissions. PVC is manufactured using toxic chemicals like chlorine and phthalates, which can leach into air, water, and soil throughout the material’s lifecycle. Once installed, PVC can continue to off-gas volatile organic compounds (VOCs), impacting indoor air quality and human health.

Disposal is just as problematic. PVC is difficult to recycle and often ends up in landfills or incinerators, where it can release harmful dioxins. That’s why we’re pursuing safer, more responsible alternatives. One of our most promising developments is a tulip-based resin that offers a low-toxicity, bio-based substitute for petroleum-derived polymers. While research is still ongoing, this resin avoids many of the harsh chemicals found in conventional plastics and supports our broader goal of creating circular, low-impact materials for the built environment.

Why Does U.S.-Based Manufacturing Matter for Sustainability?

Where something is made can be just as important as how it’s made when it comes to carbon footprint. At Flora Materials, we’re committed to manufacturing our materials entirely within the United States. Beyond the logistical advantages, domestic manufacturing helps lower emissions from global shipping, improves quality control, and supports local economies.

It also gives us the ability to build a more transparent and resilient supply chain. With ongoing global tariffs and shifting trade policies driving up the cost of imported flooring materials, our U.S.-based production model allows us to avoid costly disruptions and keep pricing competitive. By keeping our process close to home, we’re better equipped to scale responsibly, respond quickly to feedback, and create jobs that align with our sustainability values.

How Could Bio-Based Materials Be Used Beyond Flooring?

While our first product is a flooring tile, bio-based materials hold enormous potential for a wide range of construction applications—interior wall panels, acoustic insulation, ceiling tiles, and even exterior cladding.

These materials open up new possibilities for architects and designers looking for sustainable alternatives without compromising performance or aesthetics. Our goal is to build a full portfolio of bio-powered products that meet the aesthetic, structural, and performance standards of modern building materials, all while dramatically lowering environmental impact. We’re actively exploring what’s next—and we’re excited about where this material can take us.

What’s Next for Flora Materials?

Right now, Flora Materials is fine-tuning our bio-based flooring tile and preparing it for broader testing and certification with support from the U.S. Army’s SBIR Program.

Over the next year, our focus is on scaling production and ensuring our tile performs as well as—or better than—the petroleum-based products it’s designed to replace. By the end of our current research phase, we aim to produce enough bio-based flooring to support an 800-square-foot ADU project and achieve key milestones including ASTM certification, USDA BioPreferred approval, and “Made in the USA” designation.

We’re excited to work with architects, builders, and designers who want to lead the way. The future of construction isn’t just about building better—it’s about building differently. And it starts here.