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Upcycling and large-format 3D printing for sustainable architecture image

Caracol collaborated with Maire Tecnimont to advance circular production models by transforming industrial plastic waste into high-value applications. The project demonstrates how large-format additive manufacturing can extend the lifecycle of materials while enabling cost-effective and customized production.

Using recycled feedstock from MyReplast Industries, Caracol developed and validated a custom material blend suitable for large-scale 3D printing applications.Marine-tecnimont-3d-prinitng-heronam-composite3

From recycled feedstock to custom large-scale installations

Through its LFAM robotic platform, Caracol processed recycled plastic pellets to produce a range of customized architectural and furnishing elements for Maire Tecnimont’s offices and events.

Applications included a fully customized welcome desk for the “Beyond Digital” event, featuring a 3D printed relief of the company’s logo, as well as a large-scale security booth installed at the company’s headquarters in Milan.

The same material was also used to create modular furnishing elements designed to support safe workplace navigation, enabling flexible layouts and easy reconfiguration of spaces.

Production data

  • Technology: LFAM robotic system (Heron AM)
  • Material: Recycled PETG glass fiber (rPETG GF)
  • Applications: Desks, booths, modular furnishing systems
  • Process: Direct extrusion of recycled pellets into large-format components
  • Production approach: Customized, single-piece elements with no molds

This approach enables the production of large, functional components with high design flexibility and reduced reliance on traditional manufacturing processes.

Benefits and industrial value

The adoption of LFAM with recycled materials delivered significant advantages for architectural and interior applications:

  • Circular production: Upcycling of industrial plastic waste into new functional products
  • Cost reduction: Lower material and production costs for custom components
  • Waste minimization: Reduced environmental impact through reuse of materials
  • Design flexibility: Fully customizable shapes, patterns, and branding elements
  • Large-scale production: Ability to manufacture oversized components without tooling
  • Process efficiency: Direct production from pellets without intermediate steps

This project highlights how large-format additive manufacturing can enable sustainable and flexible solutions for architecture and construction, combining design, functionality, and circular economy principles.Marine-tecnimont-3d-prinitng-heronam-composite2

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