Large Format
3D PrintingLFAM

Designed for Circularity.

We are innovative thinkers pushing the boundaries of sustainable, circular fabrication in Ireland.

Large Format Additive ManufacturingZero Waste100% Circular MaterialsMade in IrelandRobotic 3D PrintingLarge Format Additive ManufacturingZero Waste100% Circular MaterialsMade in IrelandRobotic 3D Printing

[Our Story]

The Zerolab team standing beside the large format robotic printing arm

We are innovative thinkers pushing the boundaries of sustainable, circular fabrication in Ireland.

Zerolab, established in 2026, is Ireland's first ever Large Format Additive Manufacturing Hub serving fields across Design, Architecture and Engineering.

We established Zerolab with the objective of introuducing a new circular approach to manufacturing. Using advanced 3D printing technologies we transform recycled materials into tangible products, components and systems

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KUKA robotic arm printing on a plywood bed in the Zerolab workshop

Est. 2026 — Ireland

Key Achievements

A measurable step toward circular manufacturing in Ireland.

2000kg

Plastics repurposed in 2026

5.2Tonnes

Est. CO2 offset

No. 1

Large format 3D printing provider in Ireland

Close-up of a large format 3D printed architectural scale texture with flowing white layers

[Our Process]

Large Format additive Manufacturing enables us to produce full scale components directly from digital models at architectural scale.

Using robotic 3D printing, we deposit material layer by layer which allows us to fabricate complex geometries impossible via traditional manufacturing methods all whilst producing zero waste.

[Zero Waste Manufacturing]

Our Process is built around a closed loop material system. Waste plastic is processed into printable feedstock used to produce large scale components, and continuously reintroduce used material back into the system.

Prototypes, failed prints, and end of life products are recovered and recycled, ensuring material remains in circulation and waste is minimised.

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Hand holding shredded recycled plastic flake from the closed-loop material system

Large Format Additive Manufacturing is Ireland's first truly zero waste and entirely circular manufacturing approach.

Here's Why:

01
Material Effiency
LFAM uses only the material required for each design, significantly reducing offcuts and waste compared to subtractive or formwork-based methods of manufacturing.
02
100% Circular and sustainable materials
We use recycled plastics, bio-based composites, or regrind from previous prints - enabling closed-loop material cycles across product lifespans.
03
On-demand, localised production
Components can be printed close to the project site, reducing transport emissions and reliance on importing as well as enabling on demand, bespoke manufacturing.
04
Elimination of moulds and formwork
Printing directly from digital files removes the need for single-use tooling, cutting both waste and resource consumption.

Our Process

Large-format 3D printed column in progress, showing layered additive manufacturing texture

[Our Materials]

Close-up of recycled polymer 3D-printed surface showing layered wave texture

Recycled Polymers

Recycled and high-performance polymers for engineering and architectural applications.

Clays

Natural ceramic bodies for sculptural forms, architectural surfaces and bespoke finishes.

Concrete

Cementitious mixes formulated for structural prints, architectural elements and durable prototypes.

Research Materials

Experimental bio-based and recycled feedstocks developed for circular manufacturing.

[Recent Projects]

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Orange robotic arm printing a large purple pleated vessel on a print bed

Pleated Vessel Form

A large sculptural vessel printed in one continuous purple polymer path, its folded petals coiled straight off the robotic nozzle.

Modular Seating Run

A three-part bench printed as interlocking modules, the pinched waist profile shaped to seat two people back to back.

White twisting 3D printed column being produced beside an orange robotic arm in the studio

Fluted Column

A twisting full-height column printed in white polymer, layer lines running vertically to read as carved fluting.

Blush pink 3D printed lattice screen panel with a repeating woven diamond pattern

Lattice Facade Panel

A parametric screen panel printed in blush polymer, the woven diamond lattice tuned for light, airflow and shade.

[Case Study]

Kildare
County Council

In collaboration with Kildare County Council and Maynooth University, Zerolab was commissioned to develop a series of climate-positive installations designed to encourage sustainable behaviour among the people of Maynooth.

The project forms part of a wider initiative to establish Maynooth as Ireland's first decarbonised town.

Project Impact

This project demonstrated the potential of large format additive manufacturing to transform waste into high value products while introducing a new circular manufacturing capability to Ireland. Beyond the immediate outputs, it marks an important step towards establishing a more sustainable, localised, and recourse efficient approach, to manufacturing.