From March 2021 to May 2023 a German research project set out to develop a future‑oriented natural‑fiber composite made from whole wood. The aim was to create a material that is ecologically, economically and socially superior to conventional synthetic polymers. By applying a range of wood species, thermal treatments, compaction processes and sustainable additives, the project sought to elevate the natural material to a higher quality level. The resulting composites were expected to exhibit wear resistance, friction, hardness and hygroscopic behaviour that match or exceed those of synthetic polymers, thereby offering a viable bio‑based substitute for fossil‑fuel‑derived plastics in the wood‑processing sector and for manufacturers of bearings, seals and other mechanical components.

The research was organised into five work packages. Work package 1 focused on preparatory measures, while work package 2 verified methods and process parameters, including plasticisation, compaction and thermal modification. Work package 3 carried out tribological investigations using a ball‑on‑disc tribometer, a disc‑grinding machine and a drilling tribometer. Tests were performed on reference Guajakholz material and on samples filled with additional lubricating additives. Work package 4 examined the hygroscopic behaviour of modified cuboids and bushings, measuring source and deformation behaviour, form and positional deviations, and source pressure. Work package 5, which interacted dynamically with the other packages, provided the basis for publications and project evaluation. The project schedule included a three‑month pause for parental leave, which was incorporated cost‑neutrally into the planned timeline.

Key technical outcomes include the demonstration that the modified wood composites achieve wear resistance, friction coefficients and hardness values comparable to or better than those of conventional polymers. Tribological tests revealed that the addition of sustainable lubricating additives further reduced friction and wear. Hygroscopic studies showed that the modified cuboids and bushings maintained dimensional stability under varying humidity, with measured source pressures indicating improved resistance to moisture‑induced deformation. These findings provide a detailed understanding of the underlying phenomena and establish a solid technical foundation for the development of environmentally friendly mechanical components.

Collaboration was central to the project’s success. The Institute for Process Engineering and Plastics at TU Chemnitz contributed expert discussions and was fully integrated into the project, providing critical insights into material processing and performance. Deutsche Holzveredelung Schmeing GmbH & Co. KG participated through online conferences, offering industry perspectives and facilitating the translation of research results into practical applications. The project was funded by German research agencies, ensuring alignment with national priorities for sustainable materials development. The partnership structure enabled a close exchange of knowledge between academia and industry, fostering a pathway from laboratory research to market‑ready products. The project’s outcomes lay the groundwork for subsequent phases, where the developed composites can be scaled up and further optimised for commercial use, thereby advancing the adoption of bio‑based materials in the mechanical and wood‑processing sectors.