zërowaste.zërocompromise.zërolimits.
A New Approach to Making
Large-format 3D printing allows us to produce only what is needed, with zero waste and no excess inventory.
At zërolab, sustainability is built into the process - from how materials are sourced to how products are designed, used, and recovered. Our goal is simple: reduce waste, extend material life, and rethink how things are made.
Building locally,
thinking circularly
Our approach to circular innovation is focused on building a local material ecosystem within Ireland. One that retains value, reduces waste, and rethinks how materials are used.
To achieve this, we are working across multiple industries and sectors to identify, test, and reprocess waste streams that would otherwise be underutilised or lost from the system. Through ongoing research and collaboration, we explore how these materials can be transformed into viable feedstock for large-format additive manufacturing.
Our goal is to establish a connected, circular network where Irish material waste is recovered, reprocessed, and reintroduced into new products locally. By doing so, we aim to maximise environmental and economic impact, while contributing to a more resilient and forward-thinking recycling landscape in Ireland.
Interested in material collaboration?
Lets explore togetherFrom waste to product
— and back again
Our process begins with recycled plastic, which is processed into feedstock for robotic 3D printing. This material is used to create functional products, components, and prototypes.
At the end of use, materials are not discarded. Products and failed prints are collected, reprocessed, and returned to the system — creating a continuous material loop with minimal waste.
We offer a take-back programme for printed products and components, allowing items at the end of their life to be returned, broken down, and reused in future production. By designing for recyclability from the outset, we ensure materials are efficiently recovered and kept in use for as long as possible.
Customers can easily take part in this service, supporting more sustainable, environmentally friendly practices and smarter material use.
Want to get involved?
Send an email to info@zerolab.ie
- 1
3D Printed Part
A chair is 3D printed.
- 2
Sort & Shred
The part is sorted and shredded into small pieces.
- 3
Pelletize
Shredded material is melted and extruded into uniform pellets.
- 4
Pellets Ready
Pellets are now ready to be used for 3D printing.
- 5
3D Print Again
Pellets are used in a 3D printer to create new parts.
Large Format Additive Manufacturing is Ireland's first truly zero waste and entirely circular manufacturing approach.
Here's Why:
- 1
Material Efficiency
LFAM uses only the material required for each design, significantly reducing offcuts and waste compared to subtractive or formwork-based methods of manufacturing.
- 2
100% Circular and sustainable materials
We use recycled plastics, bio-based composites, or regrind from previous prints - enabling closed-loop material cycles across product lifespans.
- 3
On-demand production
Parts are printed only when they are needed, removing excess inventory, storage and the waste that comes with over-production.
- 4
Elimination of moulds
Printing direct from a digital model removes tooling, moulds and formwork entirely — along with the material and energy they consume.
Got a waste stream? Let's turn it into product.
Start a conversation