ARC Design, Sustainable Materials and Additive Manufacturing

Code: ARC1048-1

Lead teacher-researcher

Abbas Sibai, PhD
abbas.sibai@alba.edu.lb

Start date: September 2026

Research proposal

3D Printing Technology: PLA-Based Additive Manufacturing Using Mortar Aggregates and Admixtures from Spent Coffee Grounds to Produce Molds for the Creation of Solid Design Products and Industrial Applications

Abstract

Coffee, one of the most widely consumed beverages globally, generates significant environmental challenges in the form of spent coffee grounds (SCG). According to World Bank data, over 2 billion tons of SCG are produced annually, projected to reach 3.4 billion tons by 2050. Nearly 40% of this waste is landfilled, leading to the release of pollutants and greenhouse gases like methane, contributing to climate change. SCG contains compounds such as caffeine, tannins, and polyphenols, which can be harmful to the environment. This proposal approaches that challenge from within design practice. Rather than engineering a validated material system, it asks what happens when designers work directly with waste, collecting it, processing it, casting it, and shaping it into objects that carry both function and meaning. The research uses SCG as a powder aggregate within PLA-based 3D-printed mold systems, producing solid design products evaluated through visual, tactile, and critical design criteria. The emphasis throughout is on design-led material discovery: iterative, documented, and grounded in the studio.

Keywords: Spent coffee grounds, 3D printing, PLA, design products, molds, material innovation, waste recycling, sustainability.

Introduction

The industrial design sector plays a vital role in promoting environmental sustainability, focusing on eco-friendly solutions that prioritize both functionality and aesthetic appeal. This principle aligns with Louis Sullivan's maxim ‘form follows function’. Designers are increasingly exploring innovative methods to incorporate SCG into their products. For instance, UK-based company ‘Re-Worked’ produces furniture, such as easy chairs and coffee tables, from surface boards made with 100% recycled coffee and ash wood. Similarly, designer Rosalie McMillan has created Java Rock wrist bangles using a custom surface material containing 70% recycled coffee content.

The integration of SCG into product design not only addresses waste management but also opens avenues for creating unique, sustainable materials. Innovative approaches have been developed, such as Kaffeeform, which creates materials from coffee grounds combined with vegetable fibers and biopolymers. Francesco Pacelli's project ‘The Hoop’ utilizes coffee waste to produce raw materials for 3D printing, while Marina Ceccolini's ‘AgriDust’ employs food residues like coffee grounds mixed with potato starch as a binder.

Given the global overproduction of SCG and its favorable chemical composition—characterized by stability, modularity, and strength, this material presents substantial opportunities for various design applications. Researchers have investigated the characteristics of SCG for potential utilization in industrial design. SCG is rich in organic compounds, including hemicellulose, fatty acids, cellulose, lignin, proteins, and lipids. Elemental analysis shows that SCG contains approximately 54.78% carbon, 6.93% hydrogen, 3.32% nitrogen, 35.97% oxygen, and 0.04% sulfur, with specific gravity ranging from 0.6 to 1.4. The particle density of SCG is between 917-1361 kg/m³, making it suitable for lightweight design applications.

A study by Eliche-Quesada demonstrated the feasibility of using SCG in various product designs, which can enhance aesthetic appeal while reducing environmental impact. Research has also suggested that SCG can be used for thermal insulation and sound absorption, highlighting its versatility and potential in innovative design solutions.

Research hypothesis

Spent coffee grounds (SCG), one of the most widely produced wastes globally, can be for example repurposed into sustainable mortar aggregates for industrial applications by partially substituting sand with SCG. This research hypothesizes that by using PLA-based molds for casting, filled with a specially formulated SCG aggregate mix, it is possible to create solid design products and molds. This approach aims to leverage the beneficial properties of SCG, combined with other aggregates, to produce eco-friendly, durable, and functional design elements. This innovative method not only addresses the challenge of coffee waste disposal but also contributes to sustainable practices in product development through additive manufacturing and casting techniques.

Description

This ARC positions design practice as its primary method of inquiry. Students collect and process spent coffee grounds from the ALBA campus, develop SCG-based composite recipes through iterative studio experimentation, cast them into PLA-printed molds, and produce physical prototypes evaluated by design criteria: form, surface quality, coherence, and meaning. Testing is conducted through the designer’s hand and eye, through material documentation, sensory evaluation, and structured critique, rather than through engineering instrumentation. Students from different disciplines (cinema, visual communication, graphic design, product design) are each guided to discover the object that makes sense for their own creative perspective, connecting the material to a deeper question about what it holds and why it matters. The ARC produces two equally valued outputs: a material documentation archive and a physical prototype with its creative rationale.

Learning outcomes

At the end of this ARC, the student will be able to:

• Identify sustainable materials suitable for PLA-Based additive manufacturing.
• Analyze the properties and potential applications of SCG in design.
• Design functional prototypes using SCG-based composites.
• Evaluate the environmental benefits of integrating waste materials into 3D printing.
• Produce innovative solutions for sustainable product design.

Methodology

This research operates within a design-led framework, using the studio and fabrication facilities at ALBA as its primary environment. Rather than pursuing engineering-grade mechanical validation, the project positions material experimentation and prototype development as design acts in their own right. Students will collect, process, and work directly with SCG, developing composite recipes through iterative small-batch mixing and casting into PLA-based molds. Each iteration will be documented, evaluated on visual, tactile, and formal qualities, and refined through studio critique. The project involves students from diverse disciplines, cinema, visual communication, graphic design, and product design, encouraging each to bring their own disciplinary lens to the material. Industry partnerships with green and environmental organizations will be explored to ground the work in real-world sustainability practice.

Material Access, Machines and Lab Requirements Availability at ALBA

1. Access to Materials: To initiate the material collection phase, as a first step, we will leverage resources within ALBA's own campus. This approach not only simplifies logistics but also embodies our commitment to sustainability by repurposing waste generated within our university community. The process includes:

• Internal Collection Points:
o Cafeterias, Faculty Lounges, and Common Areas: We will start by collecting spent coffee grounds (SCG) from ALBA’s cafeterias, faculty lounges, and other on-campus facilities.
o Designated Collection Bins: To streamline the collection process, we will set up designated bins specifically for coffee grounds across various locations on campus. These bins will be clearly labeled and strategically placed for easy access, encouraging active participation from students, faculty, and staff.

2. Machines and Lab Requirements

o 3D Printing Compatibility: At ALBA, we have access to 3D printing machines that are equipped to print PLA molds with the possibility to try various material if accessible. The initial approach will focus on developing PLA filament that is compatible with the existing 3D printers available at ALBA, by printing standard molds using PLA. Concrete, combined with coffee grounds, will then be poured into these molds. This approach ensures flexibility and increases the chances of a successful outcome, providing the ability to adapt the method as necessary.

3. TechnicalFeasibility

o Design-Led Material Observation: Rather than relying on laboratory instruments, material evaluation in this ARC is conducted through design observation. Students assess each SCG composite batch by documenting surface texture, color, shrinkage, workability, de-molding behavior, structural cohesion, and visual porosity. These qualities are recorded photographically and in written form, creating a design-led material log that serves both as research documentation and as a basis for iterative improvement.

o Studio Evaluation and Critique: Prototypes and material samples are evaluated within the studio environment through two complementary methods. The first is sensory and visual assessment: each batch and prototype is examined for surface quality, dimensional stability, aesthetic coherence, and material behavior during forming and de-molding. The second is structured studio critique: students present their work to peers and the instructor, defending both their material decisions and their creative rationale. This dual mode of evaluation, hand, eye, and argument , is the appropriate standard for a design-discipline ARC. Where future collaboration with an external laboratory becomes possible, that data can be layered on top of the design findings as a publication-phase supplement.

4-Adhesion Properties of SCG in PLA-Based Materials

In current applications, PLA often adheres strongly to cured concrete, making post-processing and removal challenging. This excessive adhesion impacts the efficiency and reusability of molds and complicates post-production steps. Below listed some observations and suggestions

regarding the issue of PLA (polylactic acid) adhering strongly to cured concrete, which can make removal difficult after the material has dried.

• Surface Treatment of Concrete: Consider smoothing the concrete surface before printing or using a release agent, such as a mold release spray. This can help reduce the adhesion between the PLA and the concrete.
• Adjust Printing Parameters: Modifying printing settings, such as increasing the layer height and adjusting the infill percentage, might help minimize the surface area in contact with the concrete. Additionally, raising the nozzle height during the first layer could prevent excessive bonding.
• Control Cooling and Temperature: Ensure the printing environment is adequately cooled. Using a fan during the printing process can help maintain a lower temperature for the PLA, potentially reducing adhesion.
• Use of Release Agents: Applying a release agent on the concrete mold prior to printing may create a barrier that prevents strong adhesion. Options include silicone spray or a thin layer of oil.
• Experiment with Different Filaments: If PLA continues to adhere too strongly, exploring alternative 3D printing materials, such as PETG or ABS, might yield better results.
• Post-Processing Techniques: For PLA that has already adhered to the concrete, consider applying gentle heat to soften the material for easier removal. Caution is advised to prevent any damage to the concrete.
• Surface Coatings: For future projects, treating the PLA surface with a coating that minimizes adhesion, such as wax or silicone spray, can be beneficial.

4b - Creative Framework: The Object as Meaning

The aggregation process described in this research, substituting sand with spent coffee grounds (SCG) within a PLA-based mold system, is technically sound. However, the question that drives the creative dimension of this ARC is not simply: what can we make? It is: why this object, and what does it hold?

The material origin, coffee, is not incidental. Coffee is a profoundly social and ritualistic substance. It is shared, anticipated, remembered. It marks mornings, conversations, creative moments, and pauses in work. When a student transform spent coffee grounds into a physical object, they are not simply recycling waste: they are giving material form to something already embedded in human routine and culture. The object they choose to make must therefore carry the weight of that meaning. A cup made from coffee grounds closes a loop. A brick asks about permanence. A chair invites reflection on rest and labour. Each choice is an argument.

Discipline-Led Discovery

Because students enrolled in this ARC will come from diverse disciplinary backgrounds, cinema, industrial design, visual communication, and graphic arts, among others, the object they develop will not be assigned in advance. Instead, students will be guided to let their own field of practice drive the discovery of the right object. This is not an open-ended exercise without direction; it is a structured research methodology in which disciplinary thinking becomes the lens of inquiry.

A student from cinema might ask: what object holds time, narrative, or memory? They may arrive at a frame, a reel case, or a projection lens stand, objects that carry the trace of stories. A student from visual communication might ask: what object transmits or displays? They may design a display stand, a tactile map, or a modular signage component. A student from industrial design might ask: what object serves a body in space? They may develop ergonomic kitchenware, a chair component, or a planter. Each departure point is disciplinary; each arrival is material and meaningful.

The instructor will support this process through individual and group critique sessions. The creative rationale, the argument for why this object, why this form, why this material, will be developed alongside the technical prototype and treated as an equally evaluated component of the final submission.

The Three Questions Every Student Must Answer

Regardless of background, every student will be asked to develop and defend their creative rationale around three core questions:

1. Why this object? What does the choice reveal about the student’s disciplinary perspective and creative intention?

2. What does it hold? Beyond physical function, what meaning, story, or cultural value does the object contain or transmit?

3. Why coffee? How does the specific material origin, SCG, connect to or enrich the meaning of the object, beyond technical substitution?

These questions will be introduced in Session 1 and revisited throughout the semester. They form the backbone of the student’s creative dossier, which will accompany the physical prototype in the final submission.

The Instructor’s Role: Guided Autonomy

The pedagogical approach is one of guided autonomy. Students are not given the answer in advance. They are given a shared material (SCG), a shared technical process (PLA mold-making and casting), and a shared set of questions. From that common ground, each student, guided by their discipline and their own research, will discover the object that makes sense for them. The instructor will facilitate this discovery through one-on-one tutorials, group critiques, and iterative feedback on both the creative argument and the physical prototype. The goal is for each student to be able to say, by the end of the ARC: this is my object, this is why it exists, and this is what it means when it is made from what was once waste.

5-Potential Student Projects

Students can work on various projects using spent coffee grounds (SCG), including:

1. Home Accessories: Designing and prototyping items such as coasters, vases, or lampshades that utilize SCG as a primary material, showcasing its unique texture and aesthetic.
2. Furniture Design: Developing sustainable furniture pieces, like chairs or tables, that incorporate SCG-infused materials, blending functionality with eco-friendly design.
3. Consumer Products: Creating innovative consumer items, such as kitchenware or decorative objects, that highlight the recyclability and sustainability of SCG.

4. Art Installations: Designing interactive art pieces that engage the community in discussions about waste reduction and sustainability, utilizing SCG as a medium.
5. Urban Design Elements: Using strong 3D-printed molds to create street furniture and fixtures, such as flower and plant holders, benches, or public seating areas, that incorporate SCG. This project could explore the durability and aesthetic potential of SCG in outdoor environments.
6. Sustainable Landscaping Solutions: Developing prototypes for planters or garden features made from SCG-infused materials, designed for urban spaces to promote greenery and biodiversity.
7. Public Awareness Projects: Creating installations or signage for public spaces that educate the community about the benefits of recycling SCG and sustainable practices, using visually engaging designs made with SCG.
8. Functional Urban Items: Designing practical items like street furniture, waste bins, or signage that utilizes SCG, demonstrating how waste materials can be transformed into useful public amenities.

6-Methodology

1. Material Preparation:
   o Collect and preprocess SCG for use in 3D printing applications.
   o Investigate suitable admixtures and binding agents to enhance the properties of the material.
2. Determining Optimal SCG Content for Concrete Mixture: To determine the optimal amount of spent coffee grounds (SCG) to add to a concrete mixture, several factors must be considered, including the desired properties of the concrete, the characteristics of the SCG, and the specific application of the final product. The following steps outline the systematic approach to establish the right mix ratio:

o Literature Review: Review existing research on the use of SCG in concrete or other composite materials. Look for studies that have tested various proportions and reported on their effects on strength, durability, and workability.

o Initial Mix Design: Start with common mix designs for concrete and substitute a small percentage of the fine aggregates or cement with SCG. Typical initial substitution rates can range from 5% to 20% by weight.

o Batch Testing: Prepare small batches of concrete with varying SCG proportions (e.g., 0%, 5%, 10%, 15%, and 20%). Keep the total weight of the mix constant to ensure comparability.

o Design Observation and Batch Documentation: For each batch, record surface texture, color, shrinkage, cracking, workability during mixing, ease of de-molding, and tactile feel after curing. Photograph every stage. Change only one variable per batch (binder ratio, SCG proportion, drying temperature) to build a clear picture of cause and effect.
o Evaluate Aesthetic and Formal Performance: Assess how the composite performs as a design material: does it hold detail from the mold? Is the surface finish acceptable? Does it behave consistently across repeated batches? These questions guide iteration in the same way engineering data guides optimization in a laboratory context.
o Adjust Proportions Based on Results: Based on the mechanical and durability test results, adjust the SCG content. If the initial mixes show promise, explore higher percentages while ensuring the concrete still meets performance criteria.

o Consult with Experts: Engage with material scientists or concrete technologists who can provide insights based on their experience with SCG or similar materials.

o Field Trials: Once a suitable mix is identified in lab tests, consider conducting field trials to assess the performance of the concrete in real-world conditions.
o Example Starting Point: A common starting point might be to replace 10% of the cement weight with SCG while maintaining the overall water-cement ratio as per standard practices. Adjust based on the results from your tests.

3. 3D Printing of Molds and Products:

o Design and prototype molds and design products using 3D printing technology, optimizing for functionality and aesthetic appeal.

o Test different designs to evaluate effectiveness in product applications.

4. Evaluation and Analysis:

o Assess the environmental impact of using SCG in product design compared to traditional materials.

o Collect data on the mechanical and aesthetic properties of the SCG-based products.

5. Dissemination of Findings:
   o Share research outcomes through academic publications, presentations, and workshops to engage the industrial design community.

Assessment

1. Attendance (10%)
2. Follow-up on CRC lectures (20%)
3. Mid-term submission: Prototype development using SCG composites (30%)
4. Final submission: Comprehensive project report and presentation (40%)

References

• • Coffee Grounds and Environmental Impact
  Moreno, J. R., & Espinosa, J. (2020). Environmental impact of coffee production and
• consumption. Environmental Science & Technology, 54(4), 2135-2145. DOI: 10.1021/acs.est.9b05833
• • Using Spent Coffee Grounds in Product Design
  Eliche-Quesada, D., & Maroto-Valer, M. M. (2017). Utilization of spent coffee grounds as a sustainable material in product design. Materials & Design, 122, 111-118. DOI: 10.1016/j.matdes.2017.03.021
• • 3D Printing Applications
  Pérez, M., & Teixeira, R. (2020). 3D printing and its applications in sustainable design. Journal of Cleaner Production, 258, 120929. DOI: 10.1016/j.jclepro.2020.120929
• • Material Innovation
  Xiang, J., et al. (2021). Sustainable design and material innovation: The role of waste materials in 3D printing technology. Sustainable Materials and Technologies, 30, e00321. DOI: 10.1016/j.susmat.2021.e00321
• • Circular Economy in Design
  Geissdoerfer, M., et al. (2018). The circular economy – A new sustainability paradigm? Journal of Cleaner Production, 143, 757-768. DOI: 10.1016/j.jclepro.2016.12.048
• • Sustainable Use of Coffee Grounds
  Hadiyanto, H., & Kartiwi, M. (2020). Potential of spent coffee grounds as sustainable material for construction applications. Journal of Environmental Management, 262, 110354. DOI: 10.1016/j.jenvman.2020.110354
• • 3D Printing with Bio-Based Materials
  Durgun, I., & Tas, A. (2020). Bio-based polymer composites for 3D printing: An overview of their applications and properties. Composites Part A: Applied Science and Manufacturing, 138, 106076. DOI: 10.1016/j.compositesa.2020.106076
• • Upcycling Waste Materials
  Jin, H., et al. (2019). A review of the properties and applications of upcycled waste materials in sustainable design. Journal of Cleaner Production, 218, 481-496. DOI: 10.1016/j.jclepro.2019.01.014
• • Circular Economy and 3D Printing
  Reiter, S., & Geyer, R. (2019). The role of additive manufacturing in the circular economy: A review of the literature. Journal of Cleaner Production, 215, 371-381. DOI: 10.1016/j.jclepro.2019.01.211
• • Impact of Waste on Sustainability
  Pérez, C. F., et al. (2020). Assessing the environmental impact of spent coffee grounds: A review of sustainability practices and life cycle assessment. Waste Management, 105, 164-172. DOI: 10.1016/j.wasman.2020.01.016
• • Material Properties of Spent Coffee Grounds
  González-García, S., et al. (2021). Mechanical and thermal properties of composites made with spent coffee grounds and their potential applications. Journal of Materials Science, 56(1), 25-41. DOI: 10.1007/s10853-020-04946-x
• • Sustainable Materials and Design Innovation
  Ashby, M. F. (2017). Materials and sustainable development. Materials Today, 20(3), 143-148. DOI: 10.1016/j.mattod.2017.02.012
• • Bio-based Composites for 3D Printing
  Mariano, M. S., et al. (2021). 3D printing of bio-based composites: A review of current practices and future trends. Composites Part B: Engineering, 224, 109225. DOI: 10.1016/j.compositesb.2021.109225

Expected results

The project is expected to produce sustainable product prototypes using SCG as the aggregate and PLA-Based additive manufacturing for the production of molds, demonstrating their viability in industrial design. This research aims to contribute to eco-friendly practices in design, fostering innovation through waste repurposing, where the design community can take critical steps toward environmental responsibility and the promotion of a circular economy.

Discussion and Conclusion

1. Benefits of This Research:

• Sustainability: This research promotes waste reduction and the circular economy by transforming SCG into valuable materials for product development.
• Innovation: Encourages students to think creatively and experiment with unconventional materials in their design process.
• Interdisciplinary Collaboration: Fosters collaboration between industrial design and material science, enhancing students' learning experiences and skill sets.
• Market Relevance: Addresses growing consumer demand for sustainable products, preparing students for future careers in environmentally-conscious industries.
  1. Relevance to the Industrial Design Research Center:

This research aligns with the goals of the Industrial Design Research Center by:

• Enhancing Research Capabilities: Contributing to ongoing studies in sustainable materials and innovative design solutions.
• Industry Engagement: Building partnerships with companies interested in sustainable practices and materials, providing students with real-world applications for their projects.
• Educational Advancement: Offering students hands-on experience with cutting-edge 3D printing technology, preparing them for future challenges in the design industry.
  1. Collaboration Opportunities:

• Collaboration Potential: The primary collaborative framework for this ARC is interdisciplinary rather than engineering-based. Students from cinema, visual communication, graphic design, and industrial design will work alongside one another, each contributing their own disciplinary methods to a shared material problem. The instructor will facilitate this exchange through joint critique sessions and individual tutorials. Beyond the studio, partnerships with sustainability-focused organizations and design practitioners will be sought to situate the work within real-world contexts. Where future access to an external testing facility becomes available, that collaboration can be pursued as a post-ARC research extension, supporting potential academic publication without being a prerequisite for the studio outcomes.

• Interdisciplinary Collaborations: The ARC is structured to make disciplinary diversity a methodological asset rather than a logistical challenge. Students from different creative fields bring different questions to the same material, and those differences are surfaced through critique, group discussion, and comparative presentation of prototypes. Connections with local sustainability initiatives, NGOs, and design-oriented businesses will be developed to extend the impact of the work beyond the campus.

2. Educational Impact:

• Curriculum Development: The findings from this research can contribute to developing new courses or workshops within the industrial design program focused on sustainability and material innovation. Engaging industry experts for guest lectures and workshops will further enhance students' learning experiences.

3. Sustainability Metrics:

• Measuring Success: Specific metrics will be outlined to assess the sustainability impact of SCG-based products, including carbon footprint reduction, resource efficiency, and recyclability. Students will present their findings through design showcases or exhibitions, facilitating community engagement with sustainability themes.

4. Market Analysis:

• Consumer Trends: As consumer preferences shift towards sustainable products, there is a rising demand for eco-friendly materials in various industries. Market analysis indicates a growing market for products made from recycled materials, driven by increasing environmental awareness among consumers. Case studies, such as those of companies successfully utilizing waste materials for product development, demonstrate the feasibility and market potential for SCG-based design products.

5. Future Directions:

• Long-Term Research Vision: Future research directions may include expanding the application of SCG to other design areas or exploring the use of additional waste materials. Findings from this research could influence industry practices and policies regarding the use of waste materials in design.

6. Call to Action:

• This proposal advocates for the adoption of sustainable practices in the industrial design field. By embracing innovative approaches to material usage, such as the integration of SCG into 3D printing, the design community can take critical steps toward environmental responsibility and the promotion of a circular economy.

Facilitators

Green Impact Dubai, Lecturer Abbas Sbeity

Lecturers

2026-2027. Semester 1

• Dr Ricardo Mbarkho
• Prof Carlo Santulli
• Dr Matteo Sambucci
• Prof Marco Valente

Materials required by the student

• Material Access, Machines and Lab Requirements
• Material Access and Cost Overview (for Students) unless available at ALBA University.

(This table outlines materials to be provided or sourced by students for their practical and prototyping activities.)

 Research Materials:

• Academic articles, journals, and research papers related to the chosen topic (e.g., sustainable materials, SCG recycling, additive manufacturing)
• Access to digital libraries and databases (e.g., JSTOR, Google Scholar, MDPI, ELSAVIER, etc)
• Books or e-books on interdisciplinary design, material science, and artistic theory

 Software and Tools:

• Design software (e.g., Rhinoceros, AutoCAD) for conceptual design and prototyping
• 3D modeling and rendering tools (e.g., KeyShot, Blender) for visualizing designs
• Data analysis software (e.g., MATLAB, Excel, or other tools for conducting material tests or design analysis)
• Collaboration and communication platforms (e.g., Google Meet, Zoom) for group discussions and progress updates

 Artistic Materials:

• Art supplies (e.g., sketchbooks, writing tools) for initial conceptual work and experiments
• Prototyping materials for physical experimentation (e.g., SCG powder, PLA composites, sand, mortar, water, other sustainable materials)
• Access to fabrication tools (e.g., 3D printer, laser cutter) for creating prototypes and models

 Equipment for Presentation and Evaluation:

• Camera or smartphone for documenting prototypes, artworks, and design progress
• Access to a presentation platform (PowerPoint) for sharing results in class or academic forums

Action plan and schedule

Total Duration:
1 Semester (10 sessions, 3 hours each)

• ~80 hours of independent student work

General Focus:
Students will explore the integration of spent coffee grounds (SCG) into sustainable 3D printing and mold-making processes using PLA-based composites.
The semester will cover material collection, experimentation, and prototype development, leading to a final presentation and documentation phase.

Key deliverables (one-semester ARC)

• Phase 1: Material Review and Experimental Framework
• Phase 2: Prototype Design and Testing
• Phase 3: Documentation and Final Presentation
  (A follow-up publication phase may occur later under CRC supervision, outside the ARC’s teaching scope.)

Detailed Schedule – One Semester (10 Sessions, 30 Hours)

Sessions 1 – 3: Introduction & Material Review

• Overview of sustainable materials and the role of SCG in additive manufacturing (DfAM).
• Literature review and group discussions on existing research.
• Definition of research question, objectives, and scope.
  Readings: Selected papers on SCG composites and sustainable design.
  Deliverables: Summary of key references and research statement.

Sessions 4 – 6: Material Experimentation & Hypothesis Testing

• Collect and preprocess spent coffee grounds from ALBA’s cafés.
• Prepare initial test mixtures combining SCG with PLA-based molds.
• Conduct small-scale material tests (texture, adhesion, surface finish).
• Document processes, challenges, and early findings.
  Readings: Case studies on eco-friendly material applications.
  Deliverables: Material samples, photos, and documentation sheets.

Sessions 7 – 9: Prototype Development

• Design and print molds using Rhino/AutoCAD and Cura.
• Cast and evaluate SCG-based composites in the printed molds.
• Analyze mechanical behavior and aesthetic properties.
• Mid-term review and feedback from peers and CRC mentors.
  Deliverables: Prototype model (functional or conceptual) and progress report.

Session 10: Final Evaluation & Presentation

• Present prototypes, research documentation, and visual boards.
• Reflect on the sustainability and design potential of SCG composites.
• Discuss continuation of results for academic publication.
  Deliverables:
• Final presentation (oral and visual).
• Consolidated research summary and reflection document.

Post-ARC Continuation (Optional CRC Phase)

After completion of the ARC, results may be expanded into a publication phase coordinated with Prof. Michael Davie. This follow-up would include editorial preparation and article submission, and would not involve registered students unless external sponsorship is secured.

Group size

• 7 – 10 participants

Language of instruction

• English

Other details

Data Verification and Plagiarism Prevention: All data, research findings, and written content for research publications will undergo a thorough verification process to ensure the integrity and authenticity of the information. To maintain academic standards, the following steps will be followed:

1. Plagiarism Check: All written content will be checked using plagiarism detection tools (e.g., Grammarly pro, Turnitin) to ensure originality and proper citation of sources. This is to prevent any inadvertent use of non-original material and ensure academic integrity.
2. Grammar and Language Review: All research documents and publications will also be reviewed using grammar-checking tools (e.g., Grammarly) to enhance the quality of writing, correct grammatical errors, and ensure clarity. This will help in maintaining a high standard of presentation for research outputs.
3. Citation and Referencing: Proper citation of sources will be ensured using standard referencing formats (e.g., APA, MLA, Chicago) to give due credit to the original authors and to avoid plagiarism.
4. Data Validation: All collected data will be cross-checked and validated to ensure accuracy. Any inconsistencies or errors identified during the research process will be corrected before publication.

Semesters

• 2026-2027. Semester 1Course sheet – 2026-2027. Semester 1 (PDF, 98 KB)