Climate change, spiralling costs, finite resources - in many sectors of industry, the need to use more efficient manufacturing processes is becoming increasingly urgent. One group of technologies that is becoming increasingly important for this is additive manufacturing, also known as 3D printing, and its various processes.

Masses of production residues are generated every day. Whether it's sludge, dust, wood flour, fruit pits, shell limestone or shells from marine animals, the Chair of Additive Manufacturing at the Institute of Machine Elements, Engineering Design and Manufacturing wants to move away from landfilling and incinerating this waste. Their aim is to reuse these residual materials in 3D printing for new products. One process used for this is binder jetting. In this process, powdered starting material is brought together in layers with a liquid binder to produce components. The process and material are customised for the resulting workpiece. There is hardly any waste. The manufacturing process is flexible and cost-effective.

So far, plastics, synthetic resins, metals and ceramics have mainly been used for additive manufacturing. In the real-world laboratory, which is available to researchers and companies and funded by the Free State of Saxony, the focus is on the recycling of natural and industrial waste materials. This offers many approaches and helps to conserve resources and reduce carbon dioxide emissions. The task of the researchers is to utilise the different properties of the materials for suitable applications.

In this way, innovative approaches for a consistent circular economy are created with partners, making it possible to open up new markets. An international project with the Jomo Kenyatta University of Agriculture and Technology in Kenya, which will run until 2025, also aims to achieve this. Residual materials from agriculture and material from water hyacinth, a harmful invasive plant species, are to be used for additive manufacturing and thus reduce the burden on the environment. In addition to technology development, the training of skilled workers and young scientists will have a lasting effect.

Another practical example from the laboratory is the production of capitals, i.e. richly decorated column heads, for the stage design of performances at Chemnitz Theatre. Miscanthus residue, also known as elephant grass, was used as the basic material for this. In the spirit of low-threshold access to innovations, companies are also invited to the real-world laboratory to test additive manufacturing for their own applications. In addition to access to new technologies, this offers the advantage of being able to test ideas without having to invest in advance.