simul⁺Reallabor SAMSax successfully completed

Saxony has set standards in 3D printing with residual materials with the simul⁺Reallabor SAMSax. The three-year project showed how industrial and agricultural waste materials can be transformed into high-quality new components using state-of-the-art additive manufacturing - a prime example of the circular economy in action. The project was completed today (7 November 2025) at the Technische Universität Bergakademie Freiberg.

The State Ministry for Infrastructure and Regional Development funded SAMSax via the simul⁺InnovationHub with almost 1.7 million euros. The Technical Universities of Freiberg, Dresden and Chemnitz were involved. The interdisciplinary consortium links companies that regularly generate large quantities of residual materials - for example from the wood processing industry or agriculture - with potential customers for the printed components. This creates new economic opportunities and value creation models that are both ecologically and economically convincing.

In total, the consortium analysed 53 different residual materials. Of these, 25 were printed and analysed in specific applications. The success of using miscanthus grass was particularly evident: innovative 3D printing technologies were used to create dimensionally stable theatre backdrops from the residual materials - including column capitals, which were used at Chemnitz Municipal Theatre.

A newly developed multi-material printer has been in operation in Freiberg since the end of 2024, setting new standards in particular with its flexibility in the use of materials. This represents a decisive step on the way to industrial application.

State Secretary Barbara Meyer emphasised at the closing event: "The SAMSax model project stands for a transformation: residual materials become a resource again, waste becomes value again. Instead of paying money for the disposal of agricultural or industrial waste materials, they are given a new shape through the use of state-of-the-art 3D printing technologies. This is not only more sustainable, it is clever and innovative."

The Rector Prof Jutta Emes (TU Bergakademie Freiberg) emphasised: "3D printing with residual materials embodies the circular economy in practice - and this is exactly what teaching, research and transfer at the TU Bergakademie Freiberg as a resource university stand for. SAMSax impressively demonstrates how we can transform residual materials into new values through scientific excellence and regional cooperation - a benefit for research, the economy and the environment at the same time."

Prof. Dr Henning Zeidler. Henning Zeidler (TU Bergakademie Freiberg), who coordinated the project, emphasises the collaboration across specialist and university boundaries: "simul+ enabled us to integrate small and medium-sized Saxon companies, regional authorities and networks into the joint research at the three technical universities through the real-world laboratory. The open and direct exchange laid the foundation for the successful transfer. With SAMSax, Saxony shows how cooperation works."

The results of SAMSax also attracted national and international attention - through presentations at over 25 trade fairs and conferences, collaborations with 17 international research institutions and numerous scientific publications. In addition, the project team succeeded in getting many young people interested in 3D printing - for example at the hands-on trade fair "makers united" in Chemnitz and Nova Gorica (Slovenia) or at the Dresden Hechtviertel Advent calendar.

The partners will continue their collaboration beyond the official end of the project. Low-threshold offers are still planned to make it easier for companies in Saxony to get started in additive manufacturing with residual materials.

SAMSax stands for Sustainable Additive Manufacturing in Saxony. The project was created in 2022 as one of the winning projects from the "simul⁺Reallabore" pilot project call by the Saxon State Ministry for Infrastructure and Regional Development (formerly the Saxon State Ministry for Regional Development). It brought together over 220 partners from science, business and administration. The aim was to open up new paths for sustainable, resource-saving production processes and to anchor additive manufacturing as a key technology in Saxony.

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