Sustainable product design by large format additive manufacturing of cork composites

In this study, a series of Acrylate-Styrene-Acrylonitrile (ASA) composites loaded with high amounts of cork agro-waste (10–30 wt.%) are developed to address the increasing demand from industry and society for more sustainable materials, with the aim of reducing the carbon footprint associated with fossil fuel-derived plastics. These materials are suitable for Material Extrusion (ME) technologies, including Large Format Additive Manufacturing (LFAM). We demonstrate that the printing conditions can be optimised to manufacture cork composites with good mechanical properties, even for large particle sizes, around 1 mm. Sustainability analysis of these composites revealed that the carbon footprint can be reduced by up to 25% for composites with 30 wt.% cork, primarily due to the reduction in ASA usage. These composites were used to print a luminaire utilising a biomimetic approach and parametric design, showcasing how new materials and innovative product design can be integrated to produce functional and sustainable prototypes.