3D printing in lighting: Making a sustainable difference

Today’s choice in lighting is 3D printed.

3D printing is a form of ‘additive manufacturing’ that creates 3D objects from a digital file. Additive manufacturing is a process where an object is created by laying down successive layers of material until the object is fully formed. Each layer is therefore a thinly sliced layer of the total object.

3D printing is the opposite of ‘subtractive manufacturing’, which is the process of cutting out or hollowing out a piece of material. 3D printing lights enables manufacturers to produce complex shapes using less material than traditional manufacturing methods. It is believed that 3D printing can have a similar revolutionary impact on the lighting market as LED did. A large part of this impact is achieved by producing products more sustainably.

3D printed luminaires make a strong case for sustainable business innovation. Lets dive right in.

Part of a circular economy: 3D printing is a highly flexible, more sustainable form of manufacturing, in which luminaires can be made with raw material that has already been recycled, tailored to the customer’s exact needs and recycled at the end of their life. In 3D printed luminaires, nearly every component may be reused or recycled – thanks to a consistent disassembly concept –, supporting the concept of a circular economy, which means moving away from linear production and consumption models, models where things are used for a short time and thrown away after use. Moving to 3D printing can, arguably, help us accelerate the shift to an economy that reuses resources wherever possible.

Good for the environment: An elementary component of ecological sustainability strategies is to move away from the use of virgin materials to produce goods. Using fewer fossil resources – and more recycled and bio-circular sources instead. 3D printing, be it constructing a house or printing lights, is the response. The answer lies in the transition to the exclusive use of mass balanced bio-circular, post-industrial recycled and post-consumer recycled material. The combination of these three sources will be required to meet the demand for sustainable raw materials.

At Signify, for instance, we produce all printed parts with at least 65% recycled or mass-balanced bio-circular plastics. This includes the use of recycled materials as well as bio-circular materials. For bio-circular materials, the entire supply chain is ISCC³ Plus certified. For example, sheets for car ports, swimming pools or illuminated advertising from the PIR waste stream. Or plastic bottles, aluminium cans, packaging material, CDs, and nylon recycled from fishing nets from the PCR waste stream. In fact, it is possible to use least 55% renewable or recycled content as input for the 3D printing process.

All printed parts are reusable and recyclable. We use no paint, no potting, no glue, and fewer screws for easy disassembly and to simplify recyclability. We cooperate with Collection & Recycling Operations (CRO) for end-of-life management. At the end of the product’s lifecycle, the materials can be easily broken down then simply shredded and recycled. What’s more, when compared with traditional luminaries, these innovative circular designs use no paint as the lamps are already pigmented, as well as less parts, and fewer screws.

Producing on demand instead of on stock: Make-to-stock (MTS) is a manufacturing method based on forecasted product demand. Once manufactured, products are kept in stock until they are sold. The alternative is called Make-to-order (MTO) which allows consumers to purchase products that are customized to their specifications. No inventory of finished goods is required, as only non 3D printed parts such as drivers or LEDs need to be stored – being able to use them for different products. This plays a huge role lowering CO2 emission rates and in designing a sustainable supply chain

As well as benefits relating to sustainability, a further benefit of 3D-printed luminaires is that the solution can be tailored to your project, whether that be the shape, colour or texture of the product. Allowing co creation and customisation of products providing design freedom. This flexibility allows for an almost unlimited number of different luminaire shapes – an impossibility with traditional production methods, which is always restricted by the mould release. With 3D printing there is no such limitation.

Individualisation and Tailoring:  Designing luminaries to suit personal tastes is one of the most alluring features of 3D printed products. With 3D printing, you can create a luminaire that features a specific theme or one that matches your decor style.

Business case: Today customers want to work with businesses and designers that design projects with sustainability in mind. By now, we know that 3D printing is a more environmentally friendly option and choosing these lights for any projects can make any practice one of choice, while also helping a business with its sustainability agenda.

Drive brand identity: Lighting can play a crucial role in creating an enjoyable shopping experience and a memorable recall for any store/location. 3D printed lights can be uniquely designed with a bespoke design for any location be it a retail store, a gym, showroom, a hotel or even an airport, bringing alive what a brand stands for, from luxury to mass appeal use.

Scalable solution: Customers can order products at a minimum quantity of just one luminaire, or scale up into the thousands for deployment across various locations, making this an even more attractive offer.

Winning by practicality: 3D printing can allow architects or specifiers design a space by using unique fittings, but it can also offer a functional use too. For example, when organisations try to switch from conventional lighting to LED, what can sometimes occur is that the fixture being replaced may not be the same size as an LED alternative. This can mean that additional items are required, such as adaptation rings or expensive changes to the ceiling. Using 3D printing this problem can be solved. The size of the housing can be changed at the point of ordering, meaning you can be sure it will fit the exact measurements of what you’re replacing. This can also help shorten the time an installation takes because there are no further adaptations to be made on site, which will, in turn, minimise the disruption to your organisation and save on labour costs.

Sustainability is by far one of the most important issues of our time. The fostering of long-term economic growth must not have a negative impact on other systems such as social or environmental. To achieve this goal, companies must address strategic and operational challenges. The message is clear: Future economic success must go hand in hand with sustainable thinking and action.

3D printing technology opens up unprecedented simple, sustainable, and fast possibilities. This enables every company in every industry to illuminate their spaces as smartly, special and sustainable as possible today. Creating a unique brand- and customer experience.