Up to 80% of the material used to produce a SINGLE frame is discarded.
EXPERIENCE &
INNOVATION
We have combined our experience in eyewear design and polymer production with our expertise in 3D printing and our shared goal of accelerating the ecological transition in the Italian fashion industry. This has led us to develop an innovative project focused on cellulose acetate waste.
Our Mission
Zestep project is committed to significantly reducing waste in the Italian eyewear industry through a direct process of recovering and transforming polymer waste into filaments for 3D printing. This opens the door to new material applications and enables efficient and, most importantly, truly sustainable recycling.
WE MADE THE FIRST 3D PRINTING FILAMENT MADE OUT OF EYEWEAR PRODUCTION WASTE.
A truly sustainable project involving the Made in Italy fashion & accessories industries.
HOW WE DID IT
FOCUS ON THE MATERIAL
After in-depth field research, during which we analyzed the quantities, formats, and characteristics of the acetate sheets used by various eyewear manufacturers in Cadore, we requested and received several waste samples that would normally be discarded.
FIRST VERSION
After verifying that the material was free from metal or other contaminants, we successfully carried out the first filament extrusion test.
In 3D printing, it extrudes without issues; however, we encountered weak inter-layer adhesion, resulting in fragile prints. Achieving a filament based on different types of acetate without needing to sort them by type or manufacturer was a crucial starting point.
EXPERIMENTING WITH ACETATE
Thanks to the interest of several companies at this early stage of the project, we had the opportunity to study the material in greater depth—its variations, limitations, and the modifications needed to achieve an optimal product in terms of printability. We would like to thank Mazzucchelli S.p.A. for providing us with acetate samples to test and for their interest in the project.
COMPOUND TESTS
We then began testing and analyzing various acetate-based formulations in the lab. It was a long and costly process, but it ultimately led to innovations in both the material and the extrusion and compounding process.
Final VERSION
We have finally reached the definitive product, which boasts a biodegradability percentage of over 80%, contains only bio-based and biodegradable additives, and is extruded using an innovative technique that enables compounding in a single process, preserving both material quality and production costs.
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