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The first fully 3D printed robotic bar installation image

For Milan Design Week 2019 and Dutch Design Week, Caracol collaborated with Flo and Lavazza to create “The 3D Bar,” the first fully robotic 3D printed bar. The project represents a fusion of advanced design, large-format additive manufacturing, and circular economy principles, transforming industrial plastic waste into a functional architectural installation.

Designed through a generative approach, the bar features organic geometries that redefine traditional furniture aesthetics while showcasing the potential of robotic 3D printing.

Design, materials, and production approach

“The 3D Bar” was entirely produced using Caracol’s LFAM robotic system, capable of transforming industrial robots into high-speed, large-format 3D printers. This enabled the realization of complex, continuous geometries that would be difficult to achieve with conventional manufacturing.

A key aspect of the project was the use of recycled materials. Plastic waste from coffee capsules and industrial processes—provided by Flo—was processed into printable material and used to manufacture all elements of the installation, including counters and seating.

Production data

  • Technology: LFAM robotic system
  • Material: Recycled PLA + natural fibers
  • Application: Bar installation, furniture elements
  • Process: Direct printing from recycled plastic pellets and shreds
  • Production approach: Large-scale, customized components with no molds

The installation was later replicated for Lavazza at the Italian Pavilion during Dutch Design Week, demonstrating scalability and repeatability.

A new approach to design and circular manufacturing

“The 3D Bar” highlights how additive manufacturing can redefine both design and production processes:

  • Circular economy integration: Reuse of industrial plastic waste as raw material
  • Sustainable production: Reduced material waste and elimination of traditional tooling
  • Design freedom: Generative design enabling organic, complex geometries
  • Process innovation: Use of robotic systems for large-scale, high-speed printing
  • Customization: Fully tailored architectural and furniture elements
  • Material valorization: Transformation of waste into high-value design pieces

This project demonstrates how large-format additive manufacturing can merge sustainability, design, and technology, opening new possibilities for furniture and architectural applications.

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