Materials and Technology

The facade was constructed using Fused Granular Fabrication (FGF), an extrusion-based additive manufacturing method that employs granular materials, specifically pellets. This technique involves melting plastic granules and depositing them layer-by-layer to form robust 3D structures. The facade was 3D printed using O a composite material composed of a 75% thermoplastic base derived from recycled fishing nets and ropes from Northern Europe. This material undergoes a process of sorting, shredding, washing, and separation before being reinforced with glass fiber, which enhances its tensile strength and impact resistance. This innovative material was developed and refined through a collaboration between the Amsterdam-based non-profit plastics recycling company, Reflow, and the Italian 3D printing construction firm WASP.

Each year, between 500,000 and one million tonnes of ghost nets are abandoned in the ocean, causing devastating impacts on marine animals. Recycling this material not only commercialises the recovery efforts but also advances the technology. With the assistance of Aectual’s expertise in 3D printing and materials application, MVRDV's vision was realised, demonstrating the practical and environmental benefits of recycling in large-scale construction projects.

The choice of material and the 3D printing technique were critical in realising this project. The façade’s 50-millimetre-thick screen was developed to meet stringent fire safety standards, crucial for its airport setting. Thanks to the customisable properties of the FGF method, flame retardants derived from seawater were added to enhance safety.