Large-format additive manufacturing (LFAM) is rapidly changing how designers approach mobility, architecture and product development. A recent case study by Caracol AM and LG Project Management clearly illustrates this shift. Their project, THE CAB, is the world’s first fully functional 3D printed recreational vehicle (RV), produced from recycled polymer.

Recycled Materials Meet Large-Scale 3D Printing

At the core of the project lies a glass fibre-reinforced recycled PETG (rPETG GF) polymer with UV-resistant properties. This material offers strong mechanical performance, thermal stability and fire resistance. As a result, it performs well in outdoor and mobile environments.

Importantly, LFAM allows designers to place material only where needed. This reduces waste significantly. In fact, THE CAB uses around 60% less material than traditional fibreglass production. Therefore, the project demonstrates how additive manufacturing can support susatainable design strategies.

Monocoque Design Without Assembly

THE CAB features a monocoque structure that was printed as a single piece. This approach removes the need for moulds, adhesives and multi-part assembly. Consequently, it improves structural integrity and ensures better watertightness. This method opens new design possibilities. Complex, seamless geometries become easier to produce. At the same time, production becomes more efficient and less resource-intensive.

Integrated Systems And Design Freedom

Another advantage lies in the digital workflow. Designers can integrate channels and cavities directly into the printed structure. This simplifies the installation of electrical systems, plumbing and heating. In addition, this integration reduces potential failure points. It also shortens installation time. The result is a more reliable and efficient design.

Despite its lightweight construction of around 660 kg, the structure remains robust. Moreover, it can adapt to multiple uses. These include a camper, mobile office or compact living unit. This flexibility highlights the potential of LFAM across different design disciplines.

Accelerating Sustainable Production

LFAM not only improves material efficiency, but also speeds up production. THE CAB was printed in just over 90 hours. Overall, the full production process took about one week. In contrast, traditional methods would require up to three months.

This significant time reduction allows for faster prototyping and customisation. Therefore, designers can respond more quickly to changing needs and user demands.

Towards Scalable Circular Design

THE CAB shows how recycled materials and robotic 3D printing can work together. As a result, they enable scalable and customisable design solutions with a lower environmental impact.

Looking ahead, LFAM will likely expand beyond mobility applications. It already shows strong potential for architecture, interiors and product design. Ultimately, it supports a shift towards digital, circular and more adaptable production systems.

Source & photos: Caracol AM