Already, there are many projects that use additive manufacturing to make life more sustainable and greener. Professor Dr.-Ing. Claus Emmelmann set out to find the commonalities between egg cartons, sustainable 3D printing and paper. The answer is found in their project, called “Green 3D Printing,” which focuses on the production of more sustainable prototypes and models.
3D printing is a process that uses plastics to create prototypes and models. This creates waste because not all materials are sustainable and are often disposed after being used as prototypes. Considering that plastic waste is a growing problem worldwide, with 85% of the 40 million tons of municipal plastic waste generated in the U.S, going to landfill sites, the researchers at TUHH chose a more resource-conserving and environmentally friendly alternative with paper fiber materials.
Specifically the “Green 3D Printing” project is targeting printing with paper fiber materials. This papier-mâché-like material can be produced from egg cartons. It is being tested to see if it can be used in the future for 3D printing. The project, which is being funded with money from the “Calls for Transfer” program of the Science Authority, a total sum of €26,300, focuses specifically on sustainability.
The first prints were already made with paper (photo credit: BWFGB).
From Papier-Mâché to Finished 3D Printing Material
Researchers at the Technical University of Hamburg have developed a method to make paper material from egg cartons. This includes illustrative models and prototypes. The team is currently researching the right mixture of material to make it suitable for 3D printing. The additively made prototypes can be recycled in organic waste if they are also coated with a biological adhesive. TUHH’s research is not just focused on the production and use of industrial prototypes. It also considers end-use parts as well as the creation of custom packaging that can be used for shipping.
TUHH President Prof. Andreas Timms-Giel says that researchers are very happy about this project.: “We are pleased that we are once again able to support a number of innovative projects with the “Calls for Transfer” program that we initiated; especially about the TU project “Green 3D Printing” of the TU Hamburg. This is a great example of how engineering solutions can dramatically reduce our dependence on resources and help us move towards a more sustainable future. Here, 3D printing with paper fiber composites is being evaluated. This could be a viable alternative to plastic-based manufacturing of prototypes or illustrative model. The goal of the project is now to develop a prototype system to evaluate its technical and economic suitability.”
For its research in 3D printing, the Institute for Laser and Plant Systems Technology at the Technical University of Hamburg has been recognized on various international stages. This includes the Innovation Award of the German Economy 2014 for the development of industrial metal 3D printing and the Future Prize of the Federal President 2015. The patent application for the current project to produce 3D printing material is in process.
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