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[Our Process]

Layer by layer,
zero waste.

Large Format Additive Manufacturing enables us to produce full scale components directly from digital models at architectural scale.

Robotic arm printing a twisted architectural column at scale[Robotic arm printing at architectural scale]
PrintRecoverShredPelletizePrint AgainPrintRecoverShredPelletizePrint Again

What is Large format
3D Printing?

Industrial robotic arm extruding a large format 3D printed part on a plywood build platform[Robotic arm printing a large format part]

Large format additive manufacturing is a form of 3D printing used at an architectural scale.

Rather than being limited to small printed objects, large-format additive manufacturing opens up a wider range of practical applications. It can be used to create furniture, interior features, façade panels, acoustic products, industrial tooling, manufacturing aids, moulds, jigs, fixtures, prototypes and construction components.

[Why Choose It Over Traditional Manufacturing?]

Because objects are built layer by layer, large-format additive manufacturing allows complex, large-scale and highly customised forms to be produced with far fewer constraints than traditional methods. It removes the need for moulds, heavy tooling and lengthy setup processes, reducing lead times from concept to production.

Material is deposited only where it is needed, reducing waste comparatively to subtractive processes where excess material is cut away. With less tooling, less waste and fewer production stages, the process reduces the overall carbon footprint of manufacturing and enables forms that would be difficult, impossible or costly to create through conventional methods.

Geometric white 3D printed acoustic panel with layered diamond texture[Printed acoustic panel detail]
[Zero Waste Manufacturing]

Our Process is built around a closed loop material system.

Waste plastic is processed into printable feedstock used to produce large scale components, and continuously reintroduce used material back into the system.

Prototypes, failed prints, and end of life products are recovered and recycled, ensuring material remains in circulation and waste is minimised.

Hands pouring recycled polymer pellets, the raw feedstock for closed loop large format 3D printing
  1. 01

    3D Printed Part

    Full scale components printed direct from a digital model — no moulds, no formwork.

  2. 02

    Sort & Shred

    Prototypes, failed prints and end of life parts are recovered, sorted by polymer and shredded.

  3. 03

    Pelletize

    Shredded flake is extruded into consistent, printable pellets.

  4. 04

    Pellets Ready

    Feedstock is quality checked and stored, ready for the next build.

  5. 05

    3D Print Again

    Material re-enters the system and stays in circulation, print after print.

Hand holding shredded recovered polymer flake ready to be recycled into 3D printing feedstock[Shredding line — recovered polymer flake]
Close-up of a robotic print head depositing a precise bead of polymer onto a plywood build platform[Print head detail — bead deposition]
[Our Materials]
Recycled and high performance polymer feedstock for engineering and architectural 3D printing

Recycled Polymers

Raw clay material sample for ceramic large format 3D printing

Clays

Concrete mix sample for large format additive manufacturing

Concrete

Experimental research materials developed for sustainable large format 3D printing

Research Materials

Orange ABB robotic arm positioned over a plywood build platform in a bright workshop[Robotic arm in workshop]

Services

  • Application of parametric and algorthim driven workflows to create highly customised, efficient and geometrically complex solutions

  • Product Design and Development delivered end to end, from first concept through to full scale printed parts.

  • Engineering & Optimisation delivered end to end, from first concept through to full scale printed parts.

  • Large Format Manufacturing delivered end to end, from first concept through to full scale printed parts.

  • Hybrid Manufacturing delivered end to end, from first concept through to full scale printed parts.

  • Material Research & Development delivered end to end, from first concept through to full scale printed parts.

Work With Us

Have a part in mind? Let's print it.

Talk to us