Circular Lightweight Components via Large-Format Additive Manufacturing

The project idea focuses on developing circular and lightweight polymer/composite components through large-format additive manufacturing (LFAM). The aim is to combine recycled or bio-based thermoplastic materials with design for additive manufacturing, process optimisation and industrial validation to create scalable lightweight demonstrators for selected applications.

The project will investigate suitable material formulations and processing routes for LFAM, including recycled polymer composites, bio-based polymers, fibre-reinforced compounds and hybrid material approaches where relevant. The work will include material-process trials, print strategy development, dimensional and surface finishing, and validation of mechanical performance under realistic use conditions.

Başaran Technology can contribute as an industrial AM and process development partner. Its role may include DfAM support, LFAM print trials, prototype and demonstrator production, post-processing strategy, CNC finishing coordination through its partner network, surface preparation and practical manufacturability assessment. MJF and FDM technologies may also be used for functional prototypes, smaller components, design iterations and validation parts. Başaran also has experience in lightweight design and production workflows for UAV-type structural and mechanical components, including design iteration, internal geometry optimisation, part consolidation and prototype-to-production transition.

Potential demonstrators may include lightweight industrial components, composite tooling and molds, fixtures, mobility-related parts, public-use products, low-volume production parts or other application cases proposed by end-user partners.

The innovative aspect of the project is the integration of circular material streams, LFAM process development, DfAM, post-processing and physical validation within the same development cycle. Instead of focusing only on material substitution, the project aims to define practical material-process-application combinations that can turn recycled or bio-based polymer composites into validated lightweight components, tooling, fixtures or demonstrators.

We are looking for international partners with complementary expertise in recycled or bio-based polymer materials, compounding, mechanical testing, durability testing, LCA, circularity assessment, digital design/optimisation, and end-user validation. In addition, Başaran can facilitate access to local material development and compounding partners in Türkiye, as well as academic and testing infrastructure, to support material-process trials and validation activities. OEMs, industrial users, municipalities, research organisations, universities, material developers and testing institutes are welcome to join the consortium.

The expected outcome is a validated set of material-process-application combinations for circular lightweight LFAM components, supported by physical demonstrators, test results, lifecycle considerations and a clear route toward further industrial adoption.