Geelong city council has tasked Deakin University and local carpet and flooring manufacturer Godfrey Hirst with exploring a solution to convert carpet manufacturing waste into feedstock for 3D printing.
The joint research project – with funding of AU$25,000 (US$17,500) – is targeting waste material from carpet manufacturing that typically goes to landfill, to see if it can be transformed into viable feedstock for additive manufacturing. If successful, the initiative could divert hundreds of tonnes of waste annually.
The first potential application is being touted as the replacement of the Geelong waterfront bollards. The iconic wooden posts have become a local landmark – the majority were originally constructed from recycled wood repurposed from historical pier timbers.
However, after 30 years those timbers have come to the end of their expected lifespan due to fungal infections, pests, and rot caused by prolonged exposure to coastal conditions.
The prototype under development is aimed at replacing the decaying wooden structures with 3D printed versions made from recycled carpet material.
Manufacturing on Demand
The research is exploring whether the converted waste could produce bollards with improved durability and structural integrity, compared to the original timber construction.
“We’ve been working very hard behind the scenes to get the next phase of the bollards up and going, and exploring innovative technology while we do it,” stated Stretch Kontelj, Mayor of Geelong. “This project ticks a lot of boxes for us — it reflects our city’s rich history in manufacturing, it highlights where we are today in advanced manufacturing, and it contributes to the circular economy, and potentially reduces waste and landfill while preserving the legacy of our bollards that the community loves.”
The Advanced Fibre Cluster Geelong, a group of innovative companies and organisations centred around Deakin University and the Geelong region, and which accelerates the growth of Australian advanced fiber and composites capabilities, is also backing the research.
“Exploring the potential to transform carpet manufacturing waste into durable, large-scale 3D printed products aligns strongly with our commitment to waste reduction and circular economy principles,” explained Aaron Dawson, Manufacturing Manager at Godfrey Hirst. “We’re proud to collaborate locally in Geelong on a project that could deliver real environmental benefits while creating innovative, long-lasting infrastructure for the community.”
Godfrey Hirst has already developed a product in collaboration with Deakin Uni using its carpet waste material. FibreCrete takes pre-consumer carpet waste and turns it into an innovative, recycled, reinforced concrete product for multiple construction uses.
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Author: Joseph Caron-Dawe
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