In a testimony to the principles of the circular economy, an Australian partnership between industry and academia is using plastic destined to landfill to create 3D-printed houses.
Southern Cross University in Lismore and local model manufacturer Studio Kite are collaborating to address three problems at once: the amount of plastic waste in Australia, lack of housing, and the carbon footprint of building materials.
“Australia was sending a lot of plastic waste overseas, especially to China,” explained Southern Cross University’s Professor Dirk Erler. “China then changed its policy regarding accepting plastics from other countries so the waste has just been stockpiled in Australia. There are warehouses all over Australia filled with piles of plastic,” he added.
The university’s Northern Rivers Regional Circular Economy Accelerator (ReCirculator), a $2 million program funded by the Australian government, is tackling that issue by rethinking the concept of ‘waste’.
“The idea is that there is no waste, just different materials with different purposes,” said the University’s Professor Andrew Rose. “By unlocking the value of a material from one phase of use to another, it enables a model for commercially sustainable and regenerative resource use and re-use.”
ReCirculator is supplying Studio Kite with landfill-destined plastic for reuse as feedstock for its giant 3D printer, called Cadzilla.
The company started out as a manufacturer of movie props and has since expanded to create many other forms, including houses. It repurposes plastic waste to create insulated, waterproof forms. These forms are customisable in shape and are coated with high-performance cement and basalt fibre render, ensuring energy efficiency, strength, longevity, safety, and minimal carbon footprint.
“We are working out how well the materials perform, not just with structural integrity but also how long it will last over the years,” said Studio Kite’s director Steve Rosewell.
Studio Kite already launched its first 3D-printed house, called Jindi. The structure is a 32-square meter modular home designed as a self-supporting arch structure with a fire-resistant exterior and plaster interior. The company says it boasts exceptional insulation with a vermiculite-filled wall cavity ranging from 100 mm to 300mm, creating excellent passive thermal insulation. The formula is a combination of a 3D printed form made from 100% repurposed plastic and coated with a fibre reinforced high-performance cement to increase longevity.
“Coming from a theatrical and props building process and sculpting background, we wanted to perfect the building system but also make them attractive,” Rosewell explained. “We don’t have to do square boxes; we can do interesting shapes. Everyone says they are really spacious; that is because there are no corners.”
A 27-square meter Jindi studio apartments ready to move starts from under $100,000. A 2 bedroom, 60-square meter house costs from $200,000. The land and services are not included in the price.
Learn more about this circular initiative in this video.