In a project called Done & Dusted, designer Rahat Rai has developed a material made from household dust, showing how an abundant waste stream can be transformed into a usable resource. The project, created as a final-year work at Ravensbourne University, explores the possibilities of using overlooked materials in sustainable design.

From Dust to Fabric

The process starts with dust collected from vacuum cleaners. Larger debris such as tape or packaging is removed, while fine fibres and particles are kept. Rai felts the material, a technique usually used for wool, to bind the fibres together into a textile sheet.

To ensure hygiene, the material is heated to 200°C in an oven and a heat press, which kills mould spores, dust mites, and bacteria. The felt is then reinforced with a grid-like stitch pattern for strength. The result is a compostable fabric with a distinctive texture that can be adapted for different design uses.

Experiments and Material Variations

Rai carried out over 40 experiments to test how dust could be formed into different products. Techniques included mixing it with cornstarch or latex, and moulding it in 3D printed silicone moulds, and baking to change texture and density. Some results were lightweight and suitable for cushioning, while others were flexible with a rubber-like finish.

In the end, Rai returned to felting for the final prototype: a pair of slippers. The footwear highlights the tactile qualities of the dust-based textile and shows one way the material could be used in a functional product.

Circular Design Potential

Household dust is constantly produced and widely available, making it a renewable — if unusual — resource. Future developments could include blending it with natural fibres to improve strength, adding colour, or developing new textures. Rai also suggests possible commercial models, such as collecting dust from cleaning companies or hotels to make customised products.

While technical and perception challenges remain, the project shows that even everyday waste can be reconsidered as a valuable design material. The approach aligns with circular design principles, encouraging the reuse of resources that would otherwise go to landfill.

Source: Rahat Rai / James Dyson Award
Photos: Rahat Rai