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Caracol working to bridge the gap on sustainable manufacturing image

Since its foundation, Caracol has pursued additive manufacturing as a way to enable more sustainable production processes. Environmental sustainability is a core pillar of this vision, which led to the development of the MASAU project within Regione Lombardia’s initiative to promote circular economy supply chains. Developed in collaboration with ComoNExT Innovation Hub, Comune di Lomazzo, Politecnico di Milano, and LCE, the project focused on creating urban furniture that delivers both environmental and social value.

Design and production with recycled materials and Heron AM

The MASAU project aimed to give new life to recycled polypropylene, selecting a material with high recycled content, full recyclability potential, and suitability for outdoor applications.

Using Caracol’s LFAM platform Heron AM, the design and production process was optimized to reduce print time, energy consumption, material usage, and waste generation. The furniture was designed with organic shapes and arranged in a semi-circular layout to encourage social interaction.Caracol working to bridge the gap on sustainable manufacturing

The installation also integrates smart IoT features, including:

  • Smart irrigation systems for plants integrated into the structure
  • Waste collection elements to support recycling
  • Solar-powered energy supply for autonomous operation

This approach combines advanced manufacturing with functional design, creating urban elements that are both sustainable and socially engaging.

Benefits and environmental impact

The MASAU project demonstrates how LFAM can contribute to more sustainable and circular production models:

  • Use of recycled materials: High percentage of recycled polypropylene with potential for further recycling
  • Reduced resource consumption: Optimization of material usage, energy, and production time
  • On-demand production: Minimization of overproduction and inventory
  • Elimination of tooling: No molds or support materials required
  • Reduced waste: Lower impact across the supply chain
  • Localized manufacturing: Production closer to the point of use
  • Smart and functional design: Integration of IoT systems and renewable energy sources

An LCA (Life Cycle Assessment) study conducted according to ISO 14040-44 standards analyzed key environmental indicators such as CO₂ emissions, energy consumption, water usage, and waste generation, highlighting opportunities to further reduce the environmental footprint of additive manufacturing.

This project highlights how advanced manufacturing technologies can be leveraged to create solutions with a positive environmental and social impact, supporting the transition toward more sustainable production systems.

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