Journal｜Sustainable Innovation: Decoding 3D Printing and Waste Upcycling Design Part II

In the previous article "Sustainable Innovation: Decoding 3D Printing and Waste Upcycling Design Part I", we explored the inspiration behind the design of THOMAS CHIEN Restaurant, where the concept of "sustainability" permeates both the dishes on the table and the interior space, extending the brand spirit into every tangible corner. In practice, we are fortunate to work alongside experts and teams who share the same sustainable vision, and Dr. Kuo is one of them.

Review article: Sustainable Innovation: Decoding 3D Printing and Waste Upcycling Design Part I

Disrupting the Existing Equation

As the founder of the first spin-off company of National Cheng Kung University, Dr. Kuo has utilized years of academic and industry collaboration to continuously innovate and develop the recycling and upcycling of local waste materials, such as reservoir sediment, power plant fly ash, and paper mill sludge. From research and development to promotion, education, and the search for sustainable manufacturing methods, he has built a kingdom for circular materials in Taiwan. Recently, he has also begun to explore innovative paths by incorporating 3D printing and circular materials, bringing Taiwan’s production and remanufacturing processes into a more eco-friendly and land-conscious green future.

Sustainable Manufacturing: Green Solutions

The rise of 3D printing is a development we have all witnessed. In recent years, numerous international construction projects have sparked a revolution in the global architecture industry. Compared to traditional building methods, 3D printing technology not only reduces material waste, slows down the depletion of natural resources, and lessens the environmental burden, but it also offers a unique advantage in maintenance. Components can be repaired or replaced individually, managing their life cycle and easing the strain of excessive production demand, thus contributing to the protection of natural resources.

Many brands have recognized the sustainable manufacturing advantages of 3D printing, driving innovation in material flexibility and giving birth to a variety of sustainable 3D-printed products. For example, Adidas introduced the Futurecraft 3D shoes made from ocean waste, and Michelin developed 3D-printed biodegradable tires, challenging our traditional concepts of material use. This groundbreaking innovation, which eliminates the traditional demands of resources, labor, and time, has written a new verb for sustainability in the 21st century, defining a landmark green solution.

The First Circular Material 3D Printing Machine and Circular Material 3D Printed Furniture in Taiwan

This sustainable green process aligns with our ideals, providing the team with a manufacturing option that is not limited by time and reduces environmental burden. However, the practical challenges cannot be ignored, as they always bring ideals back to reality. In Taiwan, due to regulations, manufacturing suppliers, and costs, this remains a technology that has not yet become mainstream, let alone applied to building or interior structures in the short term. But every movement needs a group of people who are brave enough to carry the torch and try to drive innovation. Otherwise, the industry and technology will remain stagnant. Therefore, Dr. Kuo and we decided to ignite a small spark in southern Taiwan through the design of furniture within the restaurant. Before the design was implemented, Dr. Kuo had already spent years developing guidelines for circular material supply and production, guiding us forward on this green pioneering journey.

Left: The largest 3D printer in Taiwan.

Right: Dr. Kuo, in collaboration with Everplast, has transformed Taiwan's first circular material 3D printer.

Previously, 3D printing materials in Taiwan were still limited to plastics, cement, and other non-environmentally friendly, high-carbon substrates, casting a sustainability question over Taiwan's 3D printing industry. In response, Dr. Kuo continuously brainstormed reform solutions, focusing on the waste materials he had studied for years, with the goal of fully implementing a sustainable 3D printing process in Taiwan. However, there were no machines available in Taiwan that could support the use of recycled materials. Driven by a simple determination, Dr. Kuo began searching for a cooperative supplier, eventually finding a glimmer of hope at Everplast Machinery Company in Tainan. Everplast has long specialized in machinery equipment for pipes, profiles, granulation, and wood-plastic composites, and was able to adapt its equipment to meet the specific needs of recycling material printing. This collaboration led to the transformation of Taiwan's first 3D printer capable of using recycled materials. This breakthrough in hardware officially opens up a new future for Taiwan's 3D printing manufacturing process, one that departs from the traditional model.

With the groundbreaking machine technology and the development of recycled waste materials in place, what we lacked was practical experience and a core value for high-value applications. Together with Dr. Kuo, we focused on the localization and supply chain essence of THOMAS CHIEN Restaurant. We selected materials such as blast furnace slag from China Steel Corporation in Kaohsiung, and oyster shells, which are high in calcium and considered waste due to their difficulty in incineration or landfill. We ground these materials into powder and, through repeated testing and blending in appropriate proportions, found a substitute for cement molding with the necessary hardness. This led to the creation of Taiwan’s first 3D-printed reception counter, boat-shaped public chairs, and dining table legs, all made entirely from sustainable recycled materials without any cement content. These everyday overlooked waste materials have broken the established norms and, through an innovative production model, transformed into durable, environmentally-friendly, and feasible products. They now speak to the value of local materials and industrial technological innovation, continuing their significance under the theme of sustainability.

Continue reading: Plants and Sustainable Lighting Art Exhibition

The team ground waste oyster shells and furnace slag into powder, and through 3D printing, created a series of organic, sustainable furniture for the space.

The 3D-printed boat-shaped public chair

3D-printed table legs and countertop

This article was published in Interior Magazine, June 2024 issue.
Read more: The Taste Journey