Along the country road that leads to ATL4, a giant data center going up east of Atlanta, dozens of parked cars and pickups lean tenuously on the narrow dirt shoulders. The many out-of-state plates are typical of the phalanx of tradespeople who muster for these massive construction jobs. With tech giants, utilities, and governments budgeting upwards of US $1 trillion for capital expansion to join the global battle for AI dominance, data centers are the bunkers, factories, and skunkworks—and concrete and electricity are the fuel and ammunition.

To the casual observer, the data industry can seem incorporeal, its products conjured out of weightless bits. But as I stand beside the busy construction site for DataBank’s ATL4, what impresses me most is the gargantuan amount of material—mostly concrete—that gives shape to the goliath that will house, secure, power, and cool the hardware of AI. Big data is big concrete. And that poses a big problem.

Concrete is not just a major ingredient in data centers and the power plants being built to energize them. As the world’s most widely manufactured material, concrete—and especially the cement within it—is also a major contributor to climate change, accounting for around 6 percent of global greenhouse gas emissions. Data centers use so much concrete that the construction boom is wrecking tech giants’ commitments to eliminate their carbon emissions. Even though Google, Meta, and Microsoft have touted goals to be carbon neutral or negative by 2030, and Amazon by 2040, the industry is now moving in the wrong direction.

Last year, Microsoft’s carbon emissions jumped by over 30 percent, primarily due to the materials in its new data centers. Google’s greenhouse emissions are up by nearly 50 percent over the past five years. As data centers proliferate worldwide, Morgan Stanley projects that data centers will release about 2.5 billion tonnes of CO₂ each year by 2030—or about 40 percent of what the United States currently emits from all sources.

But even as innovations in AI and the big-data construction boom are boosting emissions for the tech industry’s hyperscalers, the reinvention of concrete could also play a big part in solving the problem. Over the last decade, there’s been a wave of innovation, some of it profit-driven, some of it from academic labs, aimed at fixing concrete’s carbon problem. Pilot plants are being fielded to capture CO ₂ from cement plants and sock it safely away. Other projects are cooking up climate-friendlier recipes for cements. And AI and other computational tools are illuminating ways to drastically cut carbon by using less cement in concrete and less concrete in data centers, power plants, and other structures.

Demand for green concrete is clearly growing. Amazon, Google, Meta, and Microsoft recently joined an initiative led by the Open Compute Project Foundation to accelerate testing and deployment of low-carbon concrete in data centers, for example. Supply is increasing, too—though it’s still minuscule compared to humanity’s enormous appetite for moldable rock. But if the green goals of big tech can jump-start innovation in low-carbon concrete and create a robust market for it as well, the boom in big data could eventually become a boon for the planet.

Hyperscaler Data Centers: So Much Concrete

At the construction site for ATL4, I’m met by Tony Qorri, the company’s big, friendly, straight-talking head of construction. He says that this giant building and four others DataBank has recently built or is planning in the Atlanta area will together add 133,000 square meters (1.44 million square feet) of floor space.

They all follow a universal template that Qorri developed to optimize the construction of the company’s ever-larger centers. At each site, trucks haul in more than a thousand prefabricated concrete pieces: wall panels, columns, and other structural elements. Workers quickly assemble the precision-measured parts. Hundreds of electricians swarm the building to wire it up in just a few days. Speed is crucial when construction delays can mean losing ground in the AI battle.

The ATL4 data center outside Atlanta is one of five being built by DataBank. Together they will add over 130,000 square meters of floor space.DataBank

That battle can be measured in new data centers and floor space. The United States is home to more than 5,000 data centers today, and the Department of Commerce forecasts that number to grow by around 450 a year through 2030. Worldwide, the number of data centers now exceeds 10,000, and analysts project another 26.5 million m² of floor space over the next five years. Here in metro Atlanta, developers broke ground last year on projects that will triple the region’s data-center capacity. Microsoft, for instance, is planning a 186,000-m² complex; big enough to house around 100,000 rack-mounted servers, it will consume 324 megawatts of electricity.

The velocity of the data-center boom means that no one is pausing to await greener cement. For now, the industry’s mantra is “Build, baby, build.”

“There’s no good substitute for concrete in these projects,” says Aaron Grubbs, a structural engineer at ATL4. The latest processors going on the racks are bigger, heavier, hotter, and far more power hungry than previous generations. As a result, “you add a lot of columns,” Grubbs says.

1,000 Companies Working on Green Concrete

Concrete may not seem an obvious star in the story of how electricity and electronics have permeated modern life. Other materials—copper and silicon, aluminum and lithium—get higher billing. But concrete provides the literal, indispensable foundation for the world’s electrical workings. It is the solid, stable, durable, fire-resistant stuff that makes power generation and distribution possible. It undergirds nearly all advanced manufacturing and telecommunications. What was true in the rapid build-out of the power industry a century ago remains true today for the data industry: Technological progress begets more growth—and more concrete. Although each generation of processor and memory squeezes more computing onto each chip, and advances in superconducting microcircuitry raise the tantalizing prospect of slashing the data center’s footprint, Qorri doesn’t think his buildings will shrink to the size of a shoebox anytime soon. “I’ve been through that kind of change before, and it seems the need for space just grows with it,” he says.

By weight, concrete is not a particularly carbon-intensive material. Creating a kilogram of steel, for instance, releases about 2.4 times as much CO₂ as a kilogram of cement does. But the global construction industry consumes about 35 billion tonnes of concrete a year. That’s about 4 tonnes for every person on the planet and twice as much as all other building materials combined. It’s that massive scale—and the associated cost and sheer number of producers—that creates both a threat to the climate and inertia that resists change.

At its Edmonton, Alberta, plant [above], Heidelberg Materials is adding systems to capture carbon dioxide produced by the manufacture of Portland cement.Heidelberg Materials North America

Yet change is afoot. When I visited the innovation center operated by the Swiss materials giant Holcim, in Lyon, France, research executives told me about the database they’ve assembled of nearly 1,000 companies working to decarbonize cement and concrete. None yet has enough traction to measurably reduce global concrete emissions. But the innovators hope that the boom in data centers—and in associated infrastructure such as new nuclear reactors and offshore wind farms, where each turbine foundation can use up to 7,500 cubic meters of concrete—may finally push green cement and concrete beyond labs, startups, and pilot plants.

Why cement production emits so much carbon

Though the terms “cement” and “concrete” are often conflated, they are not the same thing. A popular analogy in the industry is that cement is the egg in the concrete cake. Here’s the basic recipe: Blend cement with larger amounts of sand and other aggregates. Then add water, to trigger a chemical reaction with the cement. Wait a while for the cement to form a matrix that pulls all the components together. Let sit as it cures into a rock-solid mass.

Portland cement, the key binder in most of the world’s concrete, was serendipitously invented in England by William Aspdin, while he was tinkering with earlier mortars that his father, Joseph, had patented in 1824. More than a century of science has revealed the essential chemistry of how cement works in concrete, but new findings are still leading to important innovations, as well as insights into how concrete absorbs atmospheric carbon as it ages.

As in the Aspdins’ day, the process to make Portland cement still begins with limestone, a sedimentary mineral made from crystalline forms of calcium carbonate. Most of the limestone quarried for cement originated hundreds of millions of years ago, when ocean creatures mineralized calcium and carbonate in seawater to make shells, bones, corals, and other hard bits.

Cement producers often build their large plants next to limestone quarries that can supply decades’ worth of stone. The stone is crushed and then heated in stages as it is combined with lesser amounts of other minerals that typically include calcium, silicon, aluminum, and iron. What emerges from the mixing and cooking are small, hard nodules called clinker. A bit more processing, grinding, and mixing turns those pellets into powdered Portland cement, which accounts for about 90 percent of the CO₂ emitted by the production of conventional concrete [see infographic, “Roads to Cleaner Concrete”].

Karen Scrivener, shown in her lab at EPFL, has developed concrete recipes that reduce emissions by 30 to 40 percent.Stefan Wermuth/Bloomberg/Getty Images

Decarbonizing Portland cement is often called heavy industry’s “hard problem” because of two processes fundamental to its manufacture. The first process is combustion: To coax limestone’s chemical transformation into clinker, large heaters and kilns must sustain temperatures around 1,500 °C. Currently that means burning coal, coke, fuel oil, or natural gas, often along with waste plastics and tires. The exhaust from those fires generates 35 to 50 percent of the cement industry’s emissions. Most of the remaining emissions result from gaseous CO ₂ liberated by the chemical transformation of the calcium carbonate (CaCO₃) into calcium oxide (CaO), a process called calcination. That gas also usually heads straight into the atmosphere.

Concrete production, in contrast, is mainly a business of mixing cement powder with other ingredients and then delivering the slurry speedily to its destination before it sets. Most concrete in the United States is prepared to order at batch plants—souped-up materials depots where the ingredients are combined, dosed out from hoppers into special mixer trucks, and then driven to job sites. Because concrete grows too stiff to work after about 90 minutes, concrete production is highly local. There are more ready-mix batch plants in the United States than there are Burger King restaurants.

Batch plants can offer thousands of potential mixes, customized to fit the demands of different jobs. Concrete in a hundred-story building differs from that in a swimming pool. With flexibility to vary the quality of sand and the size of the stone—and to add a wide variety of chemicals—batch plants have more tricks for lowering carbon emissions than any cement plant does.

Cement plants that capture carbon

China accounts for more than half of the concrete produced and used in the world, but companies there are hard to track. Outside of China, the top three multinational cement producers—Holcim, Heidelberg Materials in Germany, and Cemex in Mexico—have launched pilot programs to snare CO₂ emissions before they escape and then bury the waste deep underground. To do that, they’re taking carbon capture and storage (CCS) technology already used in the oil and gas industry and bolting it onto their cement plants.

These pilot programs will need to scale up without eating profits—something that eluded the coal industry when it tried CCS decades ago. Tough questions also remain about where exactly to store billions of tonnes of CO ₂ safely, year after year.

The appeal of CCS for cement producers is that they can continue using existing plants while still making progress toward carbon neutrality, which trade associations have committed to reach by 2050. But with well over 3,000 plants around the world, adding CCS to all of them would take enormous investment. Currently less than 1 percent of the global supply is low-emission cement. Accenture, a consultancy, estimates that outfitting the whole industry for carbon capture could cost up to $900 billion.

“The economics of carbon capture is a monster,” says Rick Chalaturnyk, a professor of geotechnical engineering at the University of Alberta, in Edmonton, Canada, who studies carbon capture in the petroleum and power industries. He sees incentives for the early movers on CCS, however. “If Heidelberg, for example, wins the race to the lowest carbon, it will be the first [cement] company able to supply those customers that demand low-carbon products”—customers such as hyperscalers.

Though cement companies seem unlikely to invest their own billions in CCS, generous government subsidies have enticed several to begin pilot projects. Heidelberg has announced plans to start capturing CO₂ from its Edmonton operations in late 2026, transforming it into what the company claims would be “the world’s first full-scale net-zero cement plant.” Exhaust gas will run through stations that purify the CO₂ and compress it into a liquid, which will then be transported to chemical plants to turn it into products or to depleted oil and gas reservoirs for injection underground, where hopefully it will stay put for an epoch or two.

Chalaturnyk says that the scale of the Edmonton plant, which aims to capture a million tonnes of CO₂ a year, is big enough to give CCS technology a reasonable test. Proving the economics is another matter. Half the $1 billion cost for the Edmonton project is being paid by the governments of Canada and Alberta.

ROADS TO CLEANER CONCRETE

As the big-data construction boom boosts the tech industry’s emissions, the reinvention of concrete could play a major role in solving the problem.

• CONCRETE TODAY Most of the greenhouse emissions from concrete come from the production of Portland cement, which requires high heat and releases carbon dioxide (CO₂) directly into the air.

• CONCRETE TOMORROW At each stage of cement and concrete production, advances in ingredients, energy supplies, and uses of concrete promise to reduce waste and pollution.

The U.S. Department of Energy has similarly offered Heidelberg up to $500 million to help cover the cost of attaching CCS to its Mitchell, Ind., plant and burying up to 2 million tonnes of CO₂ per year below the plant. And the European Union has gone even bigger, allocating nearly €1.5 billion ($1.6 billion) from its Innovation Fund to support carbon capture at cement plants in seven of its member nations.

These tests are encouraging, but they are all happening in rich countries, where demand for concrete peaked decades ago. Even in China, concrete production has started to flatten. All the growth in global demand through 2040 is expected to come from less-affluent countries, where populations are still growing and quickly urbanizing. According to projections by the Rhodium Group, cement production in those regions is likely to rise from around 30 percent of the world’s supply today to 50 percent by 2050 and 80 percent before the end of the century.

So will rich-world CCS technology translate to the rest of the world? I asked Juan Esteban Calle Restrepo, the CEO of Cementos Argos, the leading cement producer in Colombia, about that when I sat down with him recently at his office in Medellín. He was frank. “Carbon capture may work for the U.S. or Europe, but countries like ours cannot afford that,” he said.

Better cement through chemistry

As long as cement plants run limestone through fossil-fueled kilns, they will generate excessive amounts of carbon dioxide. But there may be ways to ditch the limestone—and the kilns. Labs and startups have been finding replacements for limestone, such as calcined kaolin clay and fly ash, that don’t release CO ₂ when heated. Kaolin clays are abundant around the world and have been used for centuries in Chinese porcelain and more recently in cosmetics and paper. Fly ash—a messy, toxic by-product of coal-fired power plants—is cheap and still widely available, even as coal power dwindles in many regions.

At the Swiss Federal Institute of Technology Lausanne (EPFL), Karen Scrivener and colleagues developed cements that blend calcined kaolin clay and ground limestone with a small portion of clinker. Calcining clay can be done at temperatures low enough that electricity from renewable sources can do the job. Various studies have found that the blend, known as LC3, can reduce overall emissions by 30 to 40 percent compared to those of Portland cement.

LC3 is also cheaper to make than Portland cement and performs as well for nearly all common uses. As a result, calcined clay plants have popped up across Africa, Europe, and Latin America. In Colombia, Cementos Argos is already producing more than 2 million tonnes of the stuff annually. The World Economic Forum’s Centre for Energy and Materials counts LC3 among the best hopes for the decarbonization of concrete. Wide adoption by the cement industry, the centre reckons, “can help prevent up to 500 million tonnes of CO₂ emissions by 2030.”

In a win-win for the environment, fly ash can also be used as a building block for low- and even zero-emission concrete, and the high heat of processing neutralizes many of the toxins it contains. Ancient Romans used volcanic ash to make slow-setting but durable concrete: The Pantheon, built nearly two millennia ago with ash-based cement, is still in great shape.

Coal fly ash is a cost-effective ingredient that has reactive properties similar to those of Roman cement and Portland cement. Many concrete plants already add fresh fly ash to their concrete mixes, replacing 15 to 35 percent of the cement. The ash improves the workability of the concrete, and though the resulting concrete is not as strong for the first few months, it grows stronger than regular concrete as it ages, like the Pantheon.

University labs have tested concretes made entirely with fly ash and found that some actually outperform the standard variety. More than 15 years ago, researchers at Montana State University used concrete made with 100 percent fly ash in the floors and walls of a credit union and a transportation research center. But performance depends greatly on the chemical makeup of the ash, which varies from one coal plant to the next, and on following a tricky recipe. The decommissioning of coal-fired plants has also been making fresh fly ash scarcer and more expensive.

At Sublime Systems’ pilot plant in Massachusetts, the company is using electrochemistry instead of heat to produce lime silicate cements that can replace Portland cement.Tony Luong

That has spurred new methods to treat and use fly ash that’s been buried in landfills or dumped into ponds. Such industrial burial grounds hold enough fly ash to make concrete for decades, even after every coal plant shuts down. Utah-based Eco Material Technologies is now producing cements that include both fresh and recovered fly ash as ingredients. The company claims it can replace up to 60 percent of the Portland cement in concrete—and that a new variety, suitable for 3D printing, can substitute entirely for Portland cement.

Hive 3D Builders, a Houston-based startup, has been feeding that low-emissions concrete into robots that are printing houses in several Texas developments. “We are 100 percent Portland cement–free,” says Timothy Lankau, Hive 3D’s CEO. “We want our homes to last 1,000 years.”

Sublime Systems, a startup spun out of MIT by battery scientists, uses electrochemistry rather than heat to make low-carbon cement from rocks that don’t contain carbon. Similar to a battery, Sublime’s process uses a voltage between an electrode and a cathode to create a pH gradient that isolates silicates and reactive calcium, in the form of lime (CaO). The company mixes those ingredients together to make a cement with no fugitive carbon, no kilns or furnaces, and binding power comparable to that of Portland cement. With the help of $87 million from the U.S. Department of Energy, Sublime is building a plant in Holyoke, Mass., that will be powered almost entirely by hydroelectricity. Recently the company was tapped to provide concrete for a major offshore wind farm planned off the coast of Martha’s Vineyard.

Software takes on the hard problem of concrete

It is unlikely that any one innovation will allow the cement industry to hit its target of carbon neutrality before 2050. New technologies take time to mature, scale up, and become cost-competitive. In the meantime, says Philippe Block, a structural engineer at ETH Zurich, smart engineering can reduce carbon emissions through the leaner use of materials.

His research group has developed digital design tools that make clever use of geometry to maximize the strength of concrete structures while minimizing their mass. The team’s designs start with the soaring architectural elements of ancient temples, cathedrals, and mosques—in particular, vaults and arches—which they miniaturize and flatten and then 3D print or mold inside concrete floors and ceilings. The lightweight slabs, suitable for the upper stories of apartment and office buildings, use much less concrete and steel reinforcement and have a CO₂ footprint that’s reduced by 80 percent.

There’s hidden magic in such lean design. In multistory buildings, much of the mass of concrete is needed just to hold the weight of the material above it. The carbon savings of Block’s lighter slabs thus compound, because the size, cost, and emissions of a building’s conventional-concrete elements are slashed.

Vaulted, a Swiss startup, uses digital design tools to minimize the concrete in floors and ceilings, cutting their CO₂ footprint by 80 percent.Vaulted

In Dübendorf, Switzerland, a wildly shaped experimental building has floors, roofs, and ceilings created by Block’s structural system. Vaulted, a startup spun out of ETH, is engineering and fabricating the lighter floors of a 10-story office building under construction in Zug, Switzerland.

That country has also been a leader in smart ways to recycle and reuse concrete, rather than simply landfilling demolition rubble. This is easier said than done—concrete is tough stuff, riddled with rebar. But there’s an economic incentive: Raw materials such as sand and limestone are becoming scarcer and more costly. Some jurisdictions in Europe now require that new buildings be made from recycled and reused materials. The new addition of the Kunsthaus Zürich museum, a showcase of exquisite Modernist architecture, uses recycled material for all but 2 percent of its concrete.

As new policies goose demand for recycled materials and threaten to restrict future use of Portland cement across Europe, Holcim has begun building recycling plants that can reclaim cement clinker from old concrete. It recently turned the demolition rubble from some 1960s apartment buildings outside Paris into part of a 220-unit housing complex—touted as the first building made from 100 percent recycled concrete. The company says it plans to build concrete recycling centers in every major metro area in Europe and, by 2030, to include 30 percent recycled material in all of its cement.

Further innovations in low-carbon concrete are certain to come, particularly as the powers of machine learning are applied to the problem. Over the past decade, the number of research papers reporting on computational tools to explore the vast space of possible concrete mixes has grown exponentially. Much as AI is being used to accelerate drug discovery, the tools learn from huge databases of proven cement mixes and then apply their inferences to evaluate untested mixes.

Researchers from the University of Illinois and Chicago-based Ozinga, one of the largest private concrete producers in the United States, recently worked with Meta to feed 1,030 known concrete mixes into an AI. The project yielded a novel mix that will be used for sections of a data-center complex in DeKalb, Ill. The AI-derived concrete has a carbon footprint 40 percent lower than the conventional concrete used on the rest of the site. Ryan Cialdella, Ozinga’s vice president of innovation, smiles as he notes the virtuous circle: AI systems that live in data centers can now help cut emissions from the concrete that houses them.

A sustainable foundation for the information age

Cheap, durable, and abundant yet unsustainable, concrete made with Portland cement has been one of modern technology’s Faustian bargains. The built world is on track to double in floor space by 2060, adding 230,000 km ², or more than half the area of California. Much of that will house the 2 billion more people we are likely to add to our numbers. As global transportation, telecom, energy, and computing networks grow, their new appendages will rest upon concrete. But if concrete doesn’t change, we will perversely be forced to produce even more concrete to protect ourselves from the coming climate chaos, with its rising seas, fires, and extreme weather.

The AI-driven boom in data centers is a strange bargain of its own. In the future, AI may help us live even more prosperously, or it may undermine our freedoms, civilities, employment opportunities, and environment. But solutions to the bad climate bargain that AI’s data centers foist on the planet are at hand, if there’s a will to deploy them. Hyperscalers and governments are among the few organizations with the clout to rapidly change what kinds of cement and concrete the world uses, and how those are made. With a pivot to sustainability, concrete’s unique scale makes it one of the few materials that could do most to protect the world’s natural systems. We can’t live without concrete—but with some ambitious reinvention, we can thrive with it.

This article was updated on 04 November 2024.

As the philanthropic partner of IEEE, the IEEE Foundation expands the organization’s charitable body of work by inspiring philanthropic engagement that ignites a donor’s innermost interests and values.

One way the Foundation does so is by partnering with IEEE units to create memorial funds, which pay tribute to members, family, friends, teachers, professors, students, and others. This type of giving honors someone special while also supporting future generations of engineers and celebrating innovation.

Below are three recently created memorial funds that not only have made an impact on their beneficiaries and perpetuated the legacy of the namesake but also have a deep meaning for those who launched them.

EPICS in IEEE Fischer Mertel Community of Projects

The EPICS in IEEE Fischer Mertel Community of Projects was established to support projects “designed to inspire multidisciplinary teams of engineering students to collaborate and engineer solutions to address local community needs.”

The fund was created by the children of Joe Fischer and Herb Mertel to honor their fathers’ passion for mentoring students. Longtime IEEE members, Fischer and Mertel were active with the IEEE Electromagnetic Compatibility Society. Fischer was the society’s 1972 president and served on its board of directors for six years. Mertel served on the society’s board from 1979 to 1983 and again from 1989 to 1993.

“The EPICS in IEEE Fischer Mertel Community of Projects was established to inspire and support outstanding engineering ideas and efforts that help communities worldwide,” says Tina Mertel, Herb’s daughter. “Joe Fischer and my father had a lifelong friendship and excelled as engineering leaders and founders of their respective companies [Fischer Custom Communications and EMACO]. I think that my father would have been proud to know that their friendship and work are being honored in this way.”

The nine projects supported thus far have the potential to impact more than 104,000 people because of the work and collaboration of 190 students worldwide. The projects funded are intended to represent at least two of the EPICS in IEEE’s focus categories: education and outreach; human services; environmental; and access and abilities.

Here are a few of the projects:

• The Engineering Outreach at San Diego K–12 Schools project aims to bridge the city’s STEM education gap by sending IEEE members to schools to teach project-based lessons in mechanical, aerospace, electrical and computer engineering, as well as computer science. The project is led by the IEEE–Eta Kappa Nu honor society’s Kappa Psi chapter at the University of California San Diego and the San Diego Unified School District.
• Students from the Sahrdaya College of Engineering and Technology student branch in Kodakara, India, are developing an exoskeleton for nurses to support their lumbar spine region.
• Volunteers from the IEEE Uganda Section and local engineering students are designing and fabricating a stationary bicycle to act as a generator, providing power to families living in underserved communities. The goal of the project is to reduce air pollution caused by generators and supply reliable, affordable power to people in need.
• The IEEE Colombian Caribbean Section’s Increasing Inclusion of Visually Impaired People with a Mobile Application for English Learning project aims to ensure visually impaired students can learn to read, write, and speak English alongside their peers. The section’s members are developing a mobile app to help accomplish their goal.

IEEE AESS Michael C. Wicks Radar Student Travel Grant

The IEEE Michael C. Wicks Radar Student Travel Grant was established by IEEE Fellow Michael Wicks prior to his death in 2022. The grant provides travel support for graduate students who are the primary authors on a paper being presented at the annual IEEE Radar Conference. Wicks was an electronics engineer and a radio industry leader who was known for developing knowledge-based space-time adaptive processing. He believed in investing in the next generation and he wanted to provide an opportunity for that to happen.Ten graduate students have been awarded the Wicks grant to date. This year two students from Region 8 (Africa, Europe, Middle East) and two students from Region 10 (Asia and Pacific) were able to travel to Denver to attend the IEEE Radar Conference and present their research. The papers they presented are “Target Shape Reconstruction From Multi-Perspective Shadows in Drone-Borne SAR Systems” and “Design of Convolutional Neural Networks for Classification of Ships from ISAR Images.”

Life Fellow Fumio Koyama and IEEE Fellow Constance J. Chang-Hasnain proudly display their IEEE Nick Holonyak, Jr. Medal for Semiconductor Optoelectronic Technologies at this year’s IEEE Honors Ceremony. They are accompanied by IEEE President-Elect Kathleen Kramer and IEEE President Tom Coughlin.Robb Cohen

IEEE Nick Holonyak Jr. Medal for Semiconductor Optoelectronic Technologies

The IEEE Nick Holonyak Jr. Medal for Semiconductor Optoelectronic Technologies was created with a memorial fund supported by some of Holonyak’s former graduate students to honor his work as a professor and mentor. Presented on behalf of the IEEE Board of Directors, the medal recognizes outstanding contributions to semiconductor optoelectronic devices and systems including high-energy-efficiency semiconductor devices and electronics.

Holonyak was a prolific inventor and longtime professor of electrical engineering and physics. In 1962, while working as a scientist at General Electric’s Advanced Semiconductor Laboratory in Syracuse, N.Y., he invented the first practical visible-spectrum LED and laser diode. His innovations are the basis of the devices now used in high-efficiency light bulbs and laser diodes. He left GE in 1963 to join the University of Illinois Urbana-Champaign as a professor of electrical engineering and physics at the invitation of John Bardeen, his Ph.D. advisor and a two-time Nobel Prize winner in physics. Holonyak retired from UIUC in 2013 but continued research collaborations at the university with young faculty members.

“In addition to his remarkable technical contributions, he was an excellent teacher and mentor to graduate students and young electrical engineers,” says Russell Dupuis, one of his doctoral students. “The impact of his innovations has improved the lives of most people on the earth, and this impact will only increase with time. It was my great honor to be one of his students and to help create this important IEEE medal to ensure that his work will be remembered in the future.”

The award was presented for the first time at this year’s IEEE Honors Ceremony, in Boston, to IEEE Fellow Constance Chang-Hasnain and Life Fellow Fumio Koyama for “pioneering contributions to vertical cavity surface-emitting laser (VCSEL) and VCSEL-based photonics for optical communications and sensing.”

Establishing a memorial fund through the IEEE Foundation is a gratifying way to recognize someone who has touched your life while also advancing technology for humanity. If you are interested in learning more about memorial and tribute funds, reach out to the IEEE Foundation team: donate@ieee.org.

Every invention begins with a problem—and the creative act of seeing a problem where others might just see unchangeable reality. For one 5-year-old, the problem was simple: She liked to have her tummy rubbed as she fell asleep. But her mom, exhausted from working two jobs, often fell asleep herself while putting her daughter to bed. “So [the girl] invented a teddy bear that would rub her belly for her,” explains Stephanie Couch, executive director of the Lemelson MIT Program. Its mission is to nurture the next generation of inventors and entrepreneurs.

Anyone can learn to be an inventor, Couch says, given the right resources and encouragement. “Invention doesn’t come from some innate genius, it’s not something that only really special people get to do,” she says. Her program creates invention-themed curricula for U.S. classrooms, ranging from kindergarten to community college.

We’re biased, but we hope that little girl grows up to be an engineer. By the time she comes of age, the act of invention may be something entirely new—reflecting the adoption of novel tools and the guiding forces of new social structures. Engineers, with their restless curiosity and determination to optimize the world around them, are continuously in the process of reinventing invention.

In this special issue, we bring you stories of people who are in the thick of that reinvention today. IEEE Spectrum is marking 60 years of publication this year, and we’re celebrating by highlighting both the creative act and the grindingly hard engineering work required to turn an idea into something world changing. In these pages, we take you behind the scenes of some awe-inspiring projects to reveal how technology is being made—and remade—in our time.

Inventors Are Everywhere

Invention has long been a democratic process. The economist B. Zorina Khan of Bowdoin College has noted that the U.S. Patent and Trademark Office has always endeavored to allow essentially anyone to try their hand at invention. From the beginning, the patent examiners didn’t care who the applicants were—anyone with a novel and useful idea who could pay the filing fee was officially an inventor.

This ethos continues today. It’s still possible for an individual to launch a tech startup from a garage or go on “Shark Tank” to score investors. The Swedish inventor Simone Giertz, for example, made a name for herself with YouTube videos showing off her hilariously bizarre contraptions, like an alarm clock with an arm that slapped her awake. The MIT innovation scholar Eric von Hippel has spotlighted today’s vital ecosystem of “user innovation,” in which inventors such as Giertz are motivated by their own needs and desires rather than ambitions of mass manufacturing.

But that route to invention gets you only so far, and the limits of what an individual can achieve have become starker over time. To tackle some of the biggest problems facing humanity today, inventors need a deep-pocketed government sponsor or corporate largess to muster the equipment and collective human brainpower required.

When we think about the challenges of scaling up, it’s helpful to remember Alexander Graham Bell and his collaborator Thomas Watson. “They invent this cool thing that allows them to talk between two rooms—so it’s a neat invention, but it’s basically a gadget,” says Eric Hintz, a historian of invention at the Smithsonian Institution. “To go from that to a transcontinental long-distance telephone system, they needed a lot more innovation on top of the original invention.” To scale their invention, Hintz says, Bell and his colleagues built the infrastructure that eventually evolved into Bell Labs, which became the standard-bearer for corporate R&D.

In this issue, we see engineers grappling with challenges of scale in modern problems. Consider the semiconductor technology supported by the U.S. CHIPS and Science Act, a policy initiative aimed at bolstering domestic chip production. Beyond funding manufacturing, it also provides US $11 billion for R&D, including three national centers where companies can test and pilot new technologies. As one startup tells the tale, this infrastructure will drastically speed up the lab-to-fab process.

And then there are atomic clocks, the epitome of precision timekeeping. When researchers decided to build a commercial version, they had to shift their perspective, taking a sprawling laboratory setup and reimagining it as a portable unit fit for mass production and the rigors of the real world. They had to stop optimizing for precision and instead choose the most robust laser, and the atom that would go along with it.

These technology efforts benefit from infrastructure, brainpower, and cutting-edge new tools. One tool that may become ubiquitous across industries is artificial intelligence—and it’s a tool that could further expand access to the invention arena.

What if you had a team of indefatigable assistants at your disposal, ready to scour the world’s technical literature for material that could spark an idea, or to iterate on a concept 100 times before breakfast? That’s the promise of today’s generative AI. The Swiss company Iprova is exploring whether its AI tools can automate “eureka” moments for its clients, corporations that are looking to beat their competitors to the next big idea. The serial entrepreneur Steve Blank similarly advises young startup founders to embrace AI’s potential to accelerate product development; he even imagines testing product ideas on digital twins of customers. Although it’s still early days, generative AI offers inventors tools that have never been available before.

Measuring an Invention’s Impact

If AI accelerates the discovery process, and many more patentable ideas come to light as a result, then what? As it is, more than a million patents are granted every year, and we struggle to identify the ones that will make a lasting impact. Bryan Kelly, an economist at the Yale School of Management, and his collaborators made an attempt to quantify the impact of patents by doing a technology-assisted deep dive into U.S. patent records dating back to 1840. Using natural language processing, they identified patents that introduced novel phrasing that was then repeated in subsequent patents—an indicator of radical breakthroughs. For example, Elias Howe Jr.’s 1846 patent for a sewing machine wasn’t closely related to anything that came before but quickly became the basis of future sewing-machine patents.

Another foundational patent was the one awarded to an English bricklayer in 1824 for the invention of Portland cement, which is still the key ingredient in most of the world’s concrete. As Ted C. Fishman describes in his fascinating inquiry into the state of concrete today, this seemingly stable industry is in upheaval because of its heavy carbon emissions. The AI boom is fueling a construction boom in data centers, and all those buildings require billions of tons of concrete. Fishman takes readers into labs and startups where researchers are experimenting with climate-friendly formulations of cement and concrete. Who knows which of those experiments will result in a patent that echoes down the ages?

Some engineers start their invention process by thinking about the impact they want to make on the world. The eminent Indian technologist Raghunath Anant Mashelkar, who has popularized the idea of “Gandhian engineering”, advises inventors to work backward from “what we want to achieve for the betterment of humanity,” and to create problem-solving technologies that are affordable, durable, and not only for the elite.

Durability matters: Invention isn’t just about creating something brand new. It’s also about coming up with clever ways to keep an existing thing going. Such is the case with the Hubble Space Telescope. Originally designed to last 15 years, it’s been in orbit for twice that long and has actually gotten better with age, because engineers designed the satellite to be fixable and upgradable in space.

For all the invention activity around the globe—the World Intellectual Property Organization says that 3.5 million applications for patents were filed in 2022—it may be harder to invent something useful than it used to be. Not because “everything that can be invented has been invented,” as in the apocryphal quote attributed to the unfortunate head of the U.S. patent office in 1889. Rather, because so much education and experience are required before an inventor can even understand all the dimensions of the door they’re trying to crack open, much less come up with a strategy for doing so. Ben Jones, an economist at Northwestern’s Kellogg School of Management, has shown that the average age of great technological innovators rose by about six years over the course of the 20th century. “Great innovation is less and less the provenance of the young,” Jones concluded.

Consider designing something as complex as a nuclear fusion reactor, as Tom Clynes describes in “An Off-the-Shelf Stellarator.” Fusion researchers have spent decades trying to crack the code of commercially viable fusion—it’s more akin to a calling than a career. If they succeed, they will unlock essentially limitless clean energy with no greenhouse gas emissions or meltdown danger. That’s the dream that the physicists in a lab in Princeton, N.J., are chasing. But before they even started, they first had to gain an intimate understanding of all the wrong ways to build a fusion reactor. Once the team was ready to proceed, what they created was an experimental reactor that accelerates the design-build-test cycle. With new AI tools and unprecedented computational power, they’re now searching for the best ways to create the magnetic fields that will confine the plasma within the reactor. Already, two startups have spun out of the Princeton lab, both seeking a path to commercial fusion.

The stellarator story and many other articles in this issue showcase how one innovation leads to the next, and how one invention can enable many more. The legendary Dean Kamen, best known for mechanical devices like the Segway and the prosthetic “Luke” arm, is now trying to push forward the squishy world of biological manufacturing. In an interview, Kamen explains how his nonprofit is working on the infrastructure—bioreactors, sensors, and controls—that will enable companies to explore the possibilities of growing replacement organs. You could say that he’s inventing the launchpad so others can invent the rockets.

Sometimes everyone in a research field knows where the breakthrough is needed, but that doesn’t make it any easier to achieve. Case in point: the quest for a household humanoid robot that can perform domestic chores, switching effortlessly from frying an egg to folding laundry. Roboticists need better learning software that will enable their bots to navigate the uncertainties of the real world, and they also need cheaper and lighter actuators. Major advances in these two areas would unleash a torrent of creativity and may finally bring robot butlers into our homes.

And maybe the future roboticists who make those breakthroughs will have cause to thank Marina Umaschi Bers, a technologist at Boston College who cocreated the ScratchJr programming language and the KIBO robotics kit to teach kids the basics of coding and robotics in entertaining ways. She sees engineering as a playground, a place for children to explore and create, to be goofy or grandiose. If today’s kindergartners learn to think of themselves as inventors, who knows what they’ll create tomorrow?

Research expeditions conducted at sea using a rotating gravity machine and microscope found that the Earth’s oceans may not be absorbing as much carbon as researchers have long thought.

Oceans are believed to absorb roughly 26 percent of global carbon dioxide emissions by drawing down CO₂ from the atmosphere and locking it away. In this system, CO₂ enters the ocean, where phytoplankton and other organisms consume about 70 percent of it. When these organisms eventually die, their soft, small structures sink to the bottom of the ocean in what looks like an underwater snowfall.

This “marine snow” pulls carbon away from the surface of the ocean and sequesters it in the depths for millennia, which enables the surface waters to draw down more CO₂ from the air. It’s one of Earth’s best natural carbon-removal systems. It’s so effective at keeping atmospheric CO₂ levels in check that many research groups are trying to enhance the process with geoengineering techniques.

But the new study, published on 11 October in Science, found that the sinking particles don’t fall to the ocean floor as quickly as researchers thought. Using a custom gravity machine that simulated marine snow’s native environment, the study’s authors observed that the particles produce mucus tails that act like parachutes, putting the brakes on their descent—sometimes even bringing them to a standstill.

The physical drag leaves carbon lingering in the upper hydrosphere, rather than being safely sequestered in deeper waters. Living organisms can then consume the marine snow particles and respire their carbon back into the sea. Ultimately, this impedes the rate at which the ocean draws down and sequesters additional CO₂ from the air.

The implications are grim: Scientists’ best estimates of how much CO₂ the Earth’s oceans sequester could be way off. “We’re talking roughly hundreds of gigatonnes of discrepancy if you don’t include these marine snow tails,” says Manu Prakash, a bioengineer at Stanford University and one of the paper’s authors. The work was conducted by researchers at Stanford, Rutgers University in New Jersey, and Woods Hole Oceanographic Institution in Massachusetts.

Oceans Absorb Less CO₂ Than Expected

Researchers for years have been developing numerical models to estimate marine carbon sequestration. Those models will need to be adjusted for the slower sinking speed of marine snow, Prakash says.

The findings also have implications for startups in the fledgling marine carbon geoengineering field. These companies use techniques such as ocean alkalinity enhancement to augment the ocean’s ability to sequester carbon. Their success depends, in part, on using numerical models to prove to investors and the public that their techniques work. But their estimates are only as good as the models they use, and the scientific community’s confidence in them.

“We’re talking roughly hundreds of gigatonnes of discrepancy if you don’t include these marine snow tails.” —Manu Prakash, Stanford University

The Stanford researchers made the discovery on an expedition off the coast of Maine. There, they collected marine samples by hanging traps from their boat 80 meters deep. After pulling up a sample, the researchers quickly analyzed the contents while still on board the ship using their wheel-shaped machine and microscope.

The researchers built a microscope with a spinning wheel that simulates marine snow falling through sea water over longer distances than would otherwise be practical.Prakash Lab/Stanford

The device simulates the organisms’ vertical travel over long distances. Samples go into a wheel about the size of a vintage film reel. The wheel spins constantly, allowing suspended marine-snow particles to sink while a camera captures their every move.

The apparatus adjusts for temperature, light, and pressure to emulate marine conditions. Computational tools assess flow around the sinking particles and custom software removes noise in the data from the ship’s vibrations. To accommodate for the tilt and roll of the ship, the researchers mounted the device on a two-axis gimbal.

Slower Marine Snow Reduces Carbon Sequestration

With this setup, the team observed that sinking marine snow generates an invisible halo-shaped comet tail made of viscoelastic transparent exopolymer—a mucus-like parachute. They discovered the invisible tail by adding small beads to the seawater sample in the wheel, and analyzing the way they flowed around the marine snow. “We found that the beads were stuck in something invisible trailing behind the sinking particles,” says Rahul Chajwa, a bioengineering postdoctoral fellow at Stanford.

The tail introduces drag and buoyancy, doubling the amount of time marine snow spends in the upper 100 meters of the ocean, the researchers concluded. “This is the sedimentation law we should be following,” says Prakash, who hopes to get the results into climate models.

The study will likely help models project carbon export—the process of transporting CO₂ from the atmosphere to the deep ocean, says Lennart Bach, a marine biochemist at the University of Tasmania in Australia, who was not involved with the research. “The methodology they developed is very exciting and it’s great to see new methods coming into this research field,” he says.

But Bach cautions against extrapolating the results too far. “I don’t think the study will change the numbers on carbon export as we know them right now,” because these numbers are derived from empirical methods that would have unknowingly included the effects of the mucus tail, he says.

Marine snow may be slowed by “parachutes” of mucus while sinking, potentially lowering the rate at which the global ocean can sequester carbon in the depths.Prakash Lab/Stanford

Prakash and his team came up with the idea for the microscope while conducting research on a human parasite that can travel dozens of meters. “We would make 5- to 10-meter-tall microscopes, and one day, while packing for a trip to Madagascar, I had this ‘aha’ moment,” says Prakash. “I was like: Why are we packing all these tubes? What if the two ends of these tubes were connected?”

The group turned their linear tube into a closed circular channel—a hamster wheel approach to observing microscopic particles. Over five expeditions at sea, the team further refined the microscope’s design and fluid mechanics to accommodate marine samples, often tackling the engineering while on the boat and adjusting for flooding and high seas.

In addition to the sedimentation physics of marine snow, the team also studies other plankton that may affect climate and carbon-cycle models. On a recent expedition off the coast of Northern California, the group discovered a cell with silica ballast that makes marine snow sink like a rock, Prakash says.

The crafty gravity machine is one of Prakash’s many frugal inventions, which include an origami-inspired paper microscope, or “foldscope,” that can be attached to a smartphone, and a paper-and-string biomedical centrifuge dubbed a “paperfuge.”

A collaboration between a space company and a fashion company yields something elegant.

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