Sharing Our Concept Development Report

Turning waste clay into opportunity

We’ve just published our Concept Development Report exploring whether recycled clay from construction waste could be used for 3D printing in Wales.

The idea is simple. Wales produces large amounts of clay as a by-product of construction and soil recycling. Most of it has limited value. At the same time, we need lower-carbon materials and new ways of building more sustainably. Could one problem help solve the other?

The report was shaped by learning from international pioneers like WASP (World’s Advanced Saving Project), alongside conversations with Welsh recyclers, designers and researchers. It sets out an early, practical exploration of what might be possible - starting small, testing properly and sharing what we learn.

This isn’t about rushing to scale. It’s about feasibility first: understanding material behaviour, safety and printability, and identifying sensible entry points such as tiles, panels or garden structures before anything bigger.

If it works, the potential benefits are clear:

• less waste to landfill

• lower reliance on virgin materials

• new circular manufacturing opportunities in Wales

This report marks an early step. No hype. Just curiosity, collaboration and clear next steps.

Read the full report here.

Visiting WASP Italy: Green Cocoon Attends Open Day

In September, our Managing Director, Gráinne, spent a warm week in Bologna while attending one of the Open Days hosted by WASP (World’s Advanced Saving Project), at their headquarters in nearby Massa Lombarda.

WASP are international pioneers in large-scale 3D printing and are widely recognised for their work with clay-based construction, using natural and locally sourced materials. For Green Cocoon, this visit was about more than technology. It was about relationships, shared values and learning through direct experience.

Ekaterina Volkova (left), Gráinne Connolly (centre), Imene Abidi (right)

Seeing the work up close

The Open Day offered the chance to meet the WASP team face-to-face and begin conversations about the potential for international collaboration. A guided tour of the facility followed, giving real insight into how large-scale clay 3D printing works in practice - its opportunities, its constraints, and the care required to make it successful.

The visit ended in the garden at GAIA, WASP’s 3D-printed clay structure. Walking around and inside the building was a powerful experience. Touching the walls, noticing the smell of the clay, and feeling how light and airy the space is are things no video can fully capture.

Gráinne Connolly infront of GAIA. Wasp HQ - Massa Lombarda, Italy

Shared values

What stood out most was WASP’s values-led approach. Their work isn’t driven by rapid extraction or fast commercialisation. Instead, it centres on collaboration, open knowledge-sharing and place-based solutions.

That ethos really resonates with our own. At Green Cocoon, we’re interested in circular innovation that is open, ethical and grounded in real-world application - learning together, testing ideas, and sharing what works (and what doesn’t).

Bringing the learning home to Wales

The visit acted as a catalyst for our work back in Wales. Gráinne returned home with clear next steps for our feasibility study into the potential of 3D printing using clay by-products from construction waste.

This early-stage work will focus on understanding material properties, safety and performance before thinking about scale. It’s a careful, necessary first step, and one we’re excited to be taking with the right partners around the table.

More updates soon as the work develops.

Connecting with Gavin Griffiths Group through CEIC

Earlier this year, we connected with Gavin Griffiths Group through the CEIC (Circular Economy Innovation Communities) alumni network at Swansea University - a brilliant programme that brings together local organisations to share ideas, tackle real challenges and put circular thinking into action across Wales.

GGG is an industry leader in sustainable waste management and resource recovery, known for finding innovative ways to transform construction and demolition waste into valuable new materials. Our conversations have focused on how to unlock even more value from overlooked resources, starting with the recycled clay which is produced in their wash plant!

We’re excited to keep building on the connections and inspiration that CEIC makes possible, and we’re looking forward to seeing what we can achieve together!

Photo from Gavin Griffiths Group Recycling Facility