Researchers from Tufts University, Imperial College London, and the University of Michigan have developed a new method to transform silk into a strong and durable solid material while preserving the natural structure of silk fibres. The process avoids the use of synthetic additives and energy-intensive chemical treatments, resulting in a material that approaches the toughness of Kevlar and performs better than natural materials such as wood and bone.

The research, published in Nature Sustainability, introduces a simpler manufacturing process that keeps the original silk fiber structure intact. Traditional silk processing methods usually dissolve silk fibers into proteins before reshaping them into new materials.

The development could create new opportunities for industries looking for renewable alternatives to petroleum-based composite materials. Due to its strength, lightweight properties, and bio-based origin, the material may be suitable for applications in mobility, consumer goods, protective equipment, and lightweight structural products.

The research team also discovered that fused silk has unique optical properties. The material is transparent to visible light and can polarise terahertz radiation, which could make it useful for medical imaging, sensing technologies, and future 6G communication systems.

According to the researchers, these properties could support future medical applications such as regenerative implants and orthopaedic fixation devices used for bone fractures. The study highlights how natural fibres can be engineered into advanced materials that combine high performance with sustainability.