11/11/2025

Sika has joined forces with Gramazio Kohler Research at ETH Zurich to redefine how used thermoplastic membranes are used in the construction industry.

Through cutting-edge research and advanced manufacturing processes, this collaboration demonstrates the transformative potential of Large Scale Robotic 3D Printing (LSR3DP) using post-consumer thermoplastics.

 

The Challenge

Plastic waste from the construction industry - particularly flexible polyolefins (FPO) used in roofing membranes - is often difficult to recycle and ends up in landfills or incineration. At the same time, the demand for sustainable, high-performance building materials is rising.

Can we close the loop? Can we reimagine waste as a resource?

 

The Solution

Sika and Gramazio Kohler Research at ETH Zurich are pioneering a circular approach by converting reclaimed FPO into custom-designed, 3D-printed façade and roofing systems. These components are not only fully recyclable but retain essential technical properties such as UV and weather resistance - making them suitable for demanding architectural applications.

 

Key Innovations

  • Circular Material Flow: Reuse of post-consumer FPO in structural components
  • LSR3DP Technology: Precise, large-scale additive manufacturing without material degradation
  • Custom Design: Freedom to create tailored architectural elements beyond traditional constraints
  • Validated Performance: Retention of key material characteristics over multiple recycling cycles

Benefits for the Industry

  • Circular Economy in Practice – Real-world application of closed-loop principles in construction
  • Lower Environmental Impact – Reduced emissions and reliance on virgin resources
  • Design & Engineering Freedom – Adaptive, performance-based solutions for future-ready buildings
  • Support for EPR & Material Banks – Enabling systematic material reuse and extended producer responsibility

Video: Circularity in Action

Watch how Sika and Gramazio Kohler Research at ETH Zurich are turning old membranes into the architecture of tomorrow.

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Further Reading

Scientific Article: Post-Consumer Flexible Polyolefins (FPO) as a Material for Bespoke 3D-Printed Facades

Sika’s Commitment to Sustainability

This project is part of Sika’s broader mission to enable sustainable construction through innovation, performance, and responsibility. Together with leading academic partners, we are creating real solutions that support a more circular, resilient, and resource-efficient built environment.