NEUBAU natural PX 3 Ddruck production

natural3D

A plant-based material for our 3D printed glasses

For our 3D printing process, we use natural3D - a 100% plant-based polymer made from non-genetically modified castor oil beans. This material is not only derived from a renewable source, it also enables us to produce the frames without creating solid or cutting waste. The entire manufacturing process therefore leaves an extremely small environmental footprint. natural3D allows us to produce very robust and durable components that can be compared to those made from naturalPX. It is also solvent resistant and contains no plasticizers.

Our natural3D printed frames are extremely flexible and impact resistant. This robust material ensures that the frames retain their shape and are built to last. 3D printed frames are also extremely lightweight. The cutting-edge finishing and sealing processes used during 3D printing produces frames with a beautiful finely pored surface, so they look and feel great too.

CASTOR OIL: A High-Performance and sustainable raw material

organic farming

We source the castor bean seeds for the production of our plant-based plastics from an agricultural cooperative consisting of 2,730 certified farmers in India. The farmers are part of an initiative to promote sustainable agriculture (PRAGATI Initiative). Under this initiative, improved agricultural waste management measures are being applied. With the help of safety kits and intensive training, farmers are able to grow crops in an organic way. The castor plants we use to make our eyewear are also GMO-free.

Neubau material castor beans

FROM CASTOR OIL TO INNOVATIVE BIOPOLYMERS

Castor oil is a colorless to pale liquid with a very distinct taste and smell. The oil and its derivatives are used in a wide range of manufacturing applications, including lubricants, hydraulic and brake fluids, paints, dyes, coatings, inks and nylon. Its many remarkable properties have earned the castor oil plant the title of ​“miracle plant”, however, it is also well known for being the source of the deadly toxin ricin. Ricin is insoluble in oil which means it can be safely removed from the oil during the pressing process. Cold pressed castor oil is therefore non-toxic which is why it is also widely used in medications, cosmetics and as the base of biopolymers such as natural3D and naturalPX.

NEUBAU material castoroil bean oil powder
NEUBAU Material castor oil bean Erin

Benefits of natural 3D

Resource-saving

natural3D and naturalPX are both biobased plastics made from renewable castor oil, opposite to non-renewable petroleum-based resources that are damaging to the environment. At the moment, biobased plastics only make up 0.5% of all manufactured plastics world-wide, so we are leading the way in developing and utilizing materials that do not deplete the planet’s precious mineral resources.

Pollutant-free

The processes involved in the extraction of castor oil do not demand high levels of energy, which means carbon dioxide emissions are very low. Our customers can therefore purchase our eyewear safe in the knowledge that we are doing everything possible to minimize our company’s carbon footprint. In addition, both materials are free from harmful chemicals such as BPA, BPS and plasticizers which are major pollutants and are linked to a wide range of health problems.

Fantastic wearability

natural3D and naturalPX are not just kinder to the environment, they also have many special properties that optimize the look and feel of NEUBAU EYEWEAR. Their high elasticity and form stability also ensure that the frames fit well and retain their shape.

Beauty and flexibility in design

Our 3D frames feature subtle details, rich matte colors, and textures that are nearly impossible to achieve with conventional manufacturing methods.

Made to last

Today's environmentally conscious customers demand products that are engineered to last. Frames made from natural3D and naturalPX are designed to retain their shape and be durable - the ideal conditions for customers who follow the motto "buy less, but buy higher quality".

Skin-friendly

natural3D and naturalPX are hypoallergenic. This means that they do not cause reactions with the skin's natural chemicals or with other substances applied to the skin. Cold-pressed, non-toxic castor oil, which is the base ingredient of our plant-based polymers, is also used in numerous medications and cosmetics due to its properties.

3D printing with natural3D

Our 3D printing can most easily be described as a sintering process, where multiple layers of powdered plastic are baked into a solid part. This process is known as SLS (selective laser sintering). "Sintering" means using heating to create a solid shape without heating the plastic to the point of liquefaction. SLS proceeds as follows: heating, printing, cooling.

SURFACE TREATMENT

The parts have an opaque white finish when they come out of the printer. They have to undergo surface treatment before they can be color treated. A sand blasting process is used to remove any residues of the polyamide powder. This step is carefully executed to prevent any surface damage. The surface is then polished ready for the coloration process.

NEUBAU natural3 D 3 Ddruck production scheuer jpg

THE 3D COLORING PROCESS

Our high-tech coloring process is a well-guarded company secret. We only produce parts in monochrome shades at the moment, but we are continually developing new and innovative color options. The colors are resistant to natural chemicals (such as sweat), UV light and any type of solvent normally used by opticians.

NEUBAU natural3 D Romy 22

Sustainable aspects of 3D printing

3D printing is a more resource-efficient manufacturing method than traditional production of frames. It is especially sustainable because it only uses the material it needs during the sintering process. This results in an exceptionally efficient, zero-waste manufacturing solution.

A significant proportion of the natural3D material used in the printing process can be recycled. After each batch has been printed, 50% of the residue powder can be mixed with new powder to create a new batch of products or printing filaments. This production method does not require any extra tools, so it also saves on resources.

The ethos of circularity in manufacturing drives all our decisions and is why we introduced our closed-loop 3D manufacturing process at the beginning of 2019. Circularity is achieved by recycling residue polyamide in our production process and by ensuring waste we are unable to use can be used in other applications.

Once the old powder is no longer usable, it is collected by a specialist plastics processing company which ensures that the powder is properly recycled within environmental management guidelines. As long as the material is free of any traces of oxidation and contamination, it can be recycled in any production process that does not specifically require 100% virgin products. The manufacturer of our 3D printer covers the transport costs and acts as an intermediary between us and the recycling company. The money is used to fund social initiatives as part of their Corporate Social Responsibility program.

NEUBAU natural3 D 3 Ddruck Maurice 2
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