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Robotic 3D printing of custom design furniture image

Caracol’s LFAM technology is enabling a new approach to furniture production, combining design freedom, sustainability, and industrial efficiency. In collaboration with Elli Design, robotic additive manufacturing has been used to rethink how furniture is conceived, developed, and produced for public, commercial, and hospitality spaces.

Founded in 2021, Elli Design is an Italian startup built on three core principles: sustainability, innovation, and social responsibility. By leveraging Caracol’s Heron AM platform, the company has been able to translate these values into tangible products, introducing a new design language based on circularity, modularity, and customization.detail-3D-printing-furniture

Production with Heron AM and advanced materials

Through its collaboration with Caracol, Elli Design developed several furniture pieces and collections, including the DOUBLE armchair, the ZERO system, the SOHO dining table and chair, and the BRYANT coffee table.

Designing specifically for additive manufacturing enabled the creation of complex geometries, smooth organic shapes, and integrated functional features such as embedded hooks for simplified assembly. These elements would be difficult or require multiple steps with traditional processes like injection molding or rotomoulding.

Production data – DOUBLE armchair

  • Technology: LFAM Heron AM 300 (HV extruder)
  • Material: PLA
  • Size and weight: 60 × 50 × 73 cm, 6 kg
  • Nozzle size: 5 mm
  • 3D printing time: 12 hours
  • Lead time reduction: 2–3 days

Production data – ZERO system

  • Technology: LFAM Heron AM 300
  • Materials: rPP GF, PLA
  • Printing time: 7–12 hours depending on geometry
  • Lead time reduction: ~2 days
  • Assembly: Glue-free, with integrated functional hooks

The production approach also enabled single-piece manufacturing, eliminating assembly and reducing overall process complexity.DOUBLE-chair-project

Benefits and industrial value

The adoption of LFAM technology allowed Elli Design to achieve a highly efficient and sustainable production model:

  • Design freedom: Ability to create complex, organic shapes and unique surface patterns
  • Sustainability: Use of recycled and recyclable materials with near-zero waste generation
  • Customization: High flexibility in adapting designs to specific project requirements
  • Reduced production complexity: Elimination of molds and multiple manufacturing steps
  • Faster lead times: From concept to finished product in just a few days
  • Lightweight structures: Improved logistics and ease of handling
  • Circular design approach: Products designed for reuse, repair, and remanufacturing

This project demonstrates how large-format robotic 3D printing can transform furniture production, combining advanced manufacturing with circular design principles and Made in Italy creativity.Elli-ZERO-SOHO-lines

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