3D Printing Furniture: Sustainable Manufacturing Redefined

The 2024 Paris Olympics are fast approaching, set to kick off tomorrow! Apart from the athletic events, social media buzz about the cardboard beds in the Olympic Village continues to soar. So far, none of the controversial cardboard beds in the Paris Olympic Village have collapsed!

The Paris Olympic Organizing Committee adamantly claims that these seemingly fragile cardboard beds are not only eco-friendly but can also withstand up to 250 kilograms of weight, even enduring tests with three or four people jumping on them together.

These cardboard beds were actually first used in the 2020 Tokyo Olympics.

Some athletes have complained about the beds being too hard and uncomfortable, while others found them too low to the ground. During the 2020 Olympics, one cardboard bed famously “gave out” during a test where nine athletes were cheering and jumping on it together.

This moment was captured on a teammate’s phone and quickly went viral on social media, sparking a global discussion. In the midst of this debate over cardboard beds, 3DPAdvisor sees a smarter, more environmentally friendly, and personalized solution—3D printed furniture.

This technology not only has the potential to revolutionize our perception of furniture manufacturing but also promises to bring revolutionary changes to future Olympics.

Bringing a 3D Printer to Compete: DIY a More Reliable Bed

A blogger named 3D Luke once attempted to craft a bed using a desktop 3D printer.

First, he printed several support legs using the desktop printer.

He then affixed a few cushioned anti-slip pads to the back.

He roughly assembled the bed frame:

Next, he placed the wooden frame inside:

Preparing to place the mattress:

Voilà, the project is complete!

This DIY project offers an intriguing idea for athletes using desktop 3D printers to craft their own beds. The only hassle involved is sourcing suitable wooden pieces from a local lumber market in Paris to form the bed frame.

Six 3D-printed bed legs, along with a few wooden frames, are just as environmentally friendly as cardboard beds. Moreover, athletes come in various heights and sizes, making it feasible to customize beds of different dimensions using 3D printing.

Beyond DIY applications, 3D printing technology showcases immense potential in the furniture manufacturing sector. It not only provides interesting solutions for Olympic Village accommodations but also represents an innovative force in the furniture industry.

Follow AM Way to explore specific applications of 3D printing technology across various furniture manufacturing sectors.

Highly Customized: The Future of Personalized 3D Printed Furniture

One of the greatest advantages of 3D printing lies in its exceptional customization capabilities. For Olympic athletes or every individual user, everyone’s body shape, weight, and sleep habits are unique.

3D printing technology can produce bed frames and mattresses that perfectly conform to each athlete’s specific needs and ergonomic requirements.

In a case study by design studio Slicelab, they utilized the large-particle extrusion 3D printer EXT 1270 Titan Pellet to print a steam-molded chair measuring 33″x31″x36″ (approximately 84cm x 79cm x 91cm) in just 25 hours.

This printing speed is ten times faster than traditional filament extrusion printing, with costs reduced by tenfold.

Similar groundbreaking designs abound. German company Sandhelden has taken this customization concept to the extreme.

They use sand mold 3D printing technology to design and manufacture bathroom furniture, capable of printing 150 completely different-sized washbasins within 24 hours, with no minimum order quantity restrictions.

It’s worth noting that furniture giant IKEA, back in 2018, collaborated with designer Bea Åkerlund to launch their first series of 3D printed items using SLS (Selective Laser Sintering) technology. These items aren’t traditional furniture pieces but are designed for Ikea’s design adaptation and display purposes.

However, many other designers, like Adam Miklosi, have taken 3D printing to the next level by upgrading IKEA furniture:

Material Diversity in 3D Printed Furniture: Breaking Traditional Constraints

3D printing extends far beyond traditional plastic materials. Currently, 3D printing can utilize a variety of materials including metals, sand, wood, ceramics, and more. This flexibility allows us to choose the most suitable material based on specific needs.

Take Forust, for example. They have developed a technology that uses sawdust and binders to 3D print wooden furniture. This technology not only creates wooden furniture with a natural appearance but also significantly reduces wood waste, achieving true sustainability.

Imagine if Olympic Village beds utilized this technology—maintaining the natural feel of wood while embracing eco-friendly principles—wouldn’t that be a win-win?

Another notable example is R3direct. They use 100% recycled plastic pellets for 3D printing, reducing energy consumption and CO2 emissions while giving new purpose to discarded plastics.

This approach aligns perfectly with Olympic sustainability goals and offers an innovative solution to global plastic pollution issues.

Complex Structural Design with 3D Printing: Breaking Traditional Manufacturing Limits

3D printing technology transcends the constraints of traditional manufacturing methods, effortlessly producing complex geometric structures. This opens up limitless possibilities in furniture design.

London’s Alaska Studio, for instance, used Selective Laser Sintering (SLS) technology to 3D print legs for a table that effortlessly supports a heavy wooden tabletop.

Such intricate support structures are challenging to achieve with traditional methods but are easily accomplished with 3D printing.

Similarly, as demonstrated earlier, Slicelab’s steam-molded chair showcases 3D printing’s advantages in complex structural design. The chair’s organic curves and fluid form, which would require extensive molds and complex machining processes traditionally, are achieved seamlessly through 3D printing.

Bits & Parts’ modular chair design is another excellent example.

They used Fused Deposition Modeling (FDM) technology to create chairs in three different models, showcasing not only 3D printing’s applications in home furnishings but also its prowess in complex structural design.

Rapid Prototyping and Production with 3D Printing: Maximizing Efficiency

Another major advantage of 3D printing is its capability for rapid prototyping and production. Designers can quickly translate ideas into physical objects for testing and refinement, significantly shortening product development cycles and improving efficiency.

As mentioned earlier with Slicelab’s case, they completed the printing of a full chair in just 25 hours.

In contrast, using traditional filament extrusion printers, the same task could take four times longer, with material costs increasing two to threefold.

This efficiency advantage is particularly crucial in scenarios like the Olympics, where time for preparation is limited.

3D printing enables on-demand, near-production and small-batch production, significantly reducing costs.

Furthermore, 3D printing allows for the simultaneous management of aesthetic and highly technical elements within the same component, making it possible to obtain precise, high-quality items at very reasonable prices.

Environmental Sustainability: The Green Advantages of 3D Printing

Unlike traditional subtractive manufacturing, 3D printing operates on additive principles, significantly reducing material waste.

Dutch design firm The New Raw, for example, uses 3D printing technology to transform recycled plastics into public benches, showcasing the immense potential of 3D printing in environmental conservation.

Aectual takes it a step further by crafting outdoor planters and indoor screens entirely from 100% recycled plastics.

Hans Vermeulen, co-founder and CEO of the company, states:

“This is also a raw material, and we can use this new technology to make beautiful things. We aim to help make the heavily polluted building industry cleaner and more beautiful.”

Another notable example is the project from the Institute for Advanced Architecture of Catalonia (IAAC). They used eco-sustainable materials like rice and clay to 3D print a wall complete with stairs.

While this innovation extends beyond 3D printed furniture, it illustrates the potential applications of 3D printing in the construction industry and offers a new perspective on eco-friendly building materials.

Beyond Furniture: 3D Printing Applications in the Sports Industry

Imagine if athletes had access to 3D printers during competitions—they could do much more than print a comfortable bed.

Let’s explore other potential applications and business opportunities for 3D printing technology at the Olympics.

Customized Sports Gear: Enhancing Performance

Athletes can print tailored protective gear, shoe soles, and other equipment based on their body characteristics and competition needs.

This not only enhances comfort but also boosts athletic performance to some extent.

Take running shoes, for instance—each athlete has unique foot shapes and running styles.

Combining 3D scanning with 3D printing, this technology is already being utilized by some high-end running shoe brands, offering significant advantages to athletes.

Conclusion: The Olympic Spirit of 3D Printing, More Than Just Beds

3DPAdvisor envisions that with the continuous advancement of 3D printing technology, future Olympics may indeed witness athletes competing with 3D printers.

This innovation not only optimizes accommodation issues but also opens up endless possibilities for athletes.

3D printing meets personalized needs of athletes while embodying the Olympic ideals of sustainability.

3DPAdvisor calls for organizers, athletes, and professionals in related industries to actively explore the applications of 3D printing technology in sports.