I am curious if anyone has found any materials or methods of creating aerodynamic parts without using resin/ epoxy/ carbon/ fiberglass?
I love this craft, but hate exposing myself to the materials.
Are there any more natural methods, maybe similar to building a canoe or similar to build exterior parts for a car?
This is my ultimate challenge, to find a healthier solution to my addictive hobby.
plaster and flax?
Interesting, can you give me some more information on using these plaster/flax materials? What risks do I have using them?
I was thinking using clay would be the safest modelling tool, and can be re-used instead of thrown away- but have been stumped for a material to use for a casting material.
plaster is safe, but don’t breathe it. However, you are talking about water soluble items, that do NOT flow well into fabrics (they are solid particles, not a phase changing liquid that cures), and are VERY VERY heavy.
If you are so worried about your health, you came to the wrong field. While natural fibers are gaining popularity, you will always be stuck with resins that are not friendly. There are very few bio-resins out there, and even then…don’t drink it, and try not to get it on your skin.
You can use thermoplastics, but then you have to deal with heat (min 375f for low-grade soft PP and PE resins), and equipment that is needed to process it (hot press, ovens, etc)
If you want to cast objects, you can try chopping/milling natural fibers into, say plaster. It will give it overall breaking/cracking resistance.
here at UD, i believe we won the last SAMPE bridge building contest in natural fiber, using sheets of directional wood sheets, and glued them together. I think it was bamboo, or teek(sp?)…but you need to glue it together…with epoxy.
Do you know mais paste called cold porcelain?
It’s not for casting, it’s a material like clay but inhexpensive, flexible and has a good strenght like plastic.
It’s made with cornstarch, carpenters vinyl glue and paraffin oil, you obtain a white light plastic.
it’s possible to mix wood or other natural fiber into as reinforcement
Bio-resins and hemp/flax/basalt. You can cast alginate. But there is a great already made composite that’s cheap, biodegradable, non-hazardous, and good looking - timber.
Hard to cast timber 
Although, sawdust and water-based glue…
I am just over using toxic stuff, it ruins the experience for me- having to be wrapped up like a mummy with filters using this stuff. And or then being lazy and having periods of not being as safe as I should be (because it is so uncomfortable)- which brings me to the realisation that I would rather just stop using it altogether.
I think for styling purposes it makes the most sense to use chavant clay. All the automotive studios in California still use it- and whats best is that you can re-use it!
But for testing purposes, like on a race car and such- I would like to experiment with different woods, veneers and other natural ways to create surfaces and shapes but avoiding the toxic stuff.
It is easy to just give in and use the toxic chemicals, and composite fiber materials- but not so easy to find ways around it.
Thanks for all the material suggestions- I will look into all of them!