Pellet Printing the Future: Sustainable 3D-Printed Architecture with Recycled Ultrafuse® PETG Pellets

The construction industry, responsible for nearly 40% of global CO2 emissions, faces a pressing challenge to adopt more sustainable practices. Traditional building methods often depend on materials like glass and aluminum, which not only have significant environmental footprints but also involve complex, multi-layered production processes that complicate recycling. As Moritz Mungenast, architect and CEO of Mungenast/Morroni, explains, “Building materials and their reuse are crucial. Ideally, materials should have a closed-loop lifecycle. In the facade industry, materials are often downcycled rather than reused.”

Forward-thinking solutions, such as 3D printing with Forward AM’s recycled Ultrafuse® Pellets rPETG and WEBER additive’s DXR large-scale extrusion system, present an exciting opportunity to reimagine how facades are designed and manufactured. “With 3D printing, we can create customized designs that are like a tailored suit for each building,” Mungenast shares, emphasizing the potential to integrate insulation, ventilation, and acoustic optimization into a single component. This approach not only reduces production steps but also allows for “the use of recycled materials to create translucent facade elements,” transforming waste into high-quality architectural solutions.

Moreover, Mungenast highlights how the process bridges the gap between digital design and production: “3D printing closes that gap, allowing digital design and production to be seamlessly linked, with components ready to use straight from the printer.” By enabling localized manufacturing, the process minimizes transportation emissions, further reducing the carbon footprint.

Looking ahead, Mungenast envisions a future where the construction industry embraces circular economy principles. “At the end of their life, facades can be shredded, recycled, and printed into new facades with the same functions,” he notes. By combining sustainability, functionality, and aesthetics, innovations like these are poised to fundamentally change how we build, paving the way for a more environmentally responsible construction industry.

The success of this project lies in the synergy between advanced technology and collaborative partnerships:

• WEBER additive provided their DXR robotic extrusion system, which combines decades of extrusion experience with cutting-edge robotics.
• Forward AM supplied Ultrafuse® rPETG Pellets, a sustainable material with exceptional performance.
• Moritz Mungenast & Luc Morroni contributed the panel design, leveraging his architectural expertise to create an aesthetically stunning and functional structure.
• Schleicher Anlagenbau executed the precise printing of the panels, showcasing the capabilities of WEBER’s robotic system.

The project also demonstrated how cooperation across multiple disciplines can lead to transformative results. As Bayer noted, “By integrating our extrusion technology with Forward AM’s materials and the design expertise of Moritz Mungenast, we’ve created a showcase piece that goes beyond what any of us could have achieved alone.”

Ultrafuse® rPETG Pellets: A Material for the Future

Ultrafuse® rPETG Pellets are setting a new standard for sustainable additive manufacturing. Here’s why they’re a game-changer:

• Recycled Content: Made from recycled PETG, the material reduces waste and contributes to a circular economy.
• Aesthetic Versatility: Its translucent quality allows for creative lighting effects, as seen in the Formnext panels.
• Project stability: Excellent batch to batch stability

“Pellets are the obvious choice for large-scale 3D printing,” Bayer said. “They’re cost-effective, efficient, and deliver the performance needed for demanding applications.”

Venturing into the field of On-Demand 3D Printing Services, Ludwig Schleicher Anlagenbau utilized WEBER additive’s DXR robotic extrusion system to produce the panels. The DXR system features advanced robotic technology tailored for large-scale 3D printing.

“After meeting WEBER additive a few years ago and seeing their innovative technology, it was an easy decision for us to invest in a machine for large-scale printing,” said Ludwig Schleicher Jr., CEO at Ludwig Schleicher Anlagenbau. “3D printing gave us the opportunity to provide products to a wide field of customers.”

“The DXR system’s modularity and precision allow us to handle high-output materials like Ultrafuse® rPETG efficiently,” said Franz Bayer, Technical Sales Engineer at WEBER additive. This highly modular system combines Weber’s decades of extrusion expertise with the latest robotics to enable precise, large-scale production. From furniture to automotive components, the flexibility of DXR technology opens endless possibilities for creative and technical applications.

Collaboration at Formnext 2024

The project culminated in a dual-panel display at Formnext 2024, the world’s largest 3D printing trade fair, held in Frankfurt am Main, Germany. Each panel found its place at one of the two collaborating booths:

• The front side of the panel was displayed at the WEBER additive booth, showcasing the DXR robotic system and its capabilities.
• The back side of the panel was featured at the Forward AM booth, emphasizing the material properties of Ultrafuse® rPETG and Forward AM’s role as a leader in sustainable 3D printing materials.

This dual showcase highlighted the collaborative spirit behind the project and the shared commitment to sustainable innovation.