3D-Printed Custom Packaging Aims to Reduce Waste in Industrial Logistics

Paderborn-based startup Palprint is developing a system for sustainable packaging cycles using 3D-printed, custom-fit packaging made from 100 percent recycled PET. The German Federal Environmental Foundation (DBU) is supporting this initiative with 125,000 euros to reduce waste in industrial logistics.

Traditionally, oversized single-use packaging is common in industrial logistics, leading to material waste and storage inefficiencies. Palprint's approach uses 3D printing to create packaging precisely sized for each component, significantly minimizing waste. The company is initially focusing on the machinery and plant engineering sector, where bespoke packaging solutions are often needed.

The startup offers a comprehensive system, including 3D printers, software, and material supply. Palprint is also collaborating with Fraunhofer Institutes to develop a PET foam-based 3D printing method that accelerates production and reduces packaging weight. The materials used are designed to be nearly entirely recycled into new packaging, supporting a circular economy.

Palprint and DBU will showcase this technology at the IFAT trade fair in Munich. The long-term goal is to establish a closed-loop recycling system where used packaging is collected, reprocessed, and reused, thereby minimizing plastic waste and conserving resources. The company also plans to introduce reusable packaging options with a deposit system.