CIRCUPRINT is an experiment implemented within the CIRCULOOS Open Call 3.1 framework, aimed at demonstrating the technical, environmental and operational feasibility of using thermoplastic waste as direct feedstock for Big Area Additive Manufacturing (BAAM).
The project addresses a critical gap in circular manufacturing: the limited reuse of heterogeneous plastic waste streams in large-scale industrial processes without energy-intensive reprocessing steps.
The core objective of CIRCUPRINT is to validate a circular manufacturing route in which post-industrial or post-consumer thermoplastic waste can be directly transformed into durable, large-format functional components, supported by a sensor-enhanced BAAM system and integrated with the CIRCULOOS digital ecosystem.
- Approach and innovation
Unlike conventional recycling routes that require homogenisation, regranulation or compounding, CIRCUPRINT explores the direct use of non-standard thermoplastic waste in BAAM processes. This approach is enabled through the integration of an advanced monitoring architecture, capturing real-time data on key process parameters such as temperature distribution, energy consumption, emissions, deposition continuity and ambient conditions.
The collected data will support process optimisation, traceability and environmental assessment, while ensuring robustness and repeatability when working with variable waste feedstocks. By embedding data generation at the manufacturing stage, CIRCUPRINT aligns physical production with digital circular tools.
As experimental and demonstrator-production data become available, CIRCUPRINT will progressively integrate relevant datasets into CIRCULOOS tools. This integration will follow the formats and procedures defined by the CIRCULOOS consortium and will be performed once validated data are generated.
- Expected impact
CIRCUPRINT is expected to contribute to:
- Increased utilisation of thermoplastic waste in high-value applications
- Reduction of material and energy consumption by avoiding intermediate recycling steps
- Improved process repeatability and reduced print failure rates through real-time monitoring
- Enhanced traceability and data-driven sustainability assessment
- Demonstration of scalable, digitally enabled circular manufacturing models
The project targets municipalities, industrial waste generators, additive manufacturing users and system integrators seeking sustainable, traceable and locally deployable manufacturing solutions.
- Relevance for circular manufacturing
By combining direct waste reuse, large-scale additive manufacturing and digital integration, CIRCUPRINT demonstrates a replicable circular manufacturing micro-hub model. The experiment contributes to the broader CIRCULOOS vision of enabling data-driven, resilient and traceable circular value chains across European industrial ecosystems.
