PELLETSMART® CORK MANUFACTURING PROCESS

Welcome to the Smart Materials 3D Blog!

In today's post, we will show you the fascinating manufacturing process of one of our most innovative and sustainable materials: Smartfil ECO CORK. This unique material combines the strength of PLA with the lightness and natural texture of cork.

How do we make it? Keep reading to find out!

Spain and Cork Production

Spain, with 506,000 hectares of cork oak forests—representing 25% of the world's total—is the second-largest cork producer globally. Each year, 88,400 tons of cork are harvested, accounting for 30% of the world’s cork production.

The waste generated during the manufacturing of cork products mainly comes from cutting, molding, and finishing processes.

At Smart Materials, as a company committed to sustainability, we have reused these waste materials to create CORK.

Cork Preparation

It all starts with natural cork. First, we micronize it—a process in which it is carefully ground into fine particles suitable for 3D printing or industrial applications, such as robotic arms.

Then, the cork powder is sieved to select particles according to their intended use. Filament or pellet? The grain size makes all the difference.

Quality Control & Blending

Moisture control is crucial in this process. We check the humidity levels and, if necessary, dehumidify the material to ensure the highest quality. At the same time, we dehumidify the PLA if needed, preparing it for the next mixing phase.

Extrusion & Refinement Process

The sieved cork powder is transported via a vacuum system to the upper hoppers, from where it moves down into the side feeder screws.

This is where the magic happens! The PLA and cork are precisely dosed, ensuring the perfect ratio before entering the extrusion line.

The filament begins to take shape and passes through an air cooling bath, consolidating its structure and properties.

Pellets & Final Filament

Once cooled, the filament is chopped into small pieces and sieved again to produce uniform pellets.

These pellets are then sent to a weighing hopper, where exact quantities are prepared for packaging. For direct pellet sales, we use a vacuum-sealing system to preserve their quality.

If the goal is to create filament, the pellets are remixed with PLA and fed back into the extrusion line, resulting in a strong, eco-friendly filament—ready for your most creative 3D printing projects.

The Future of Sustainable 3D Printing

And that’s how we manufacture our Smartfil ECO CORK—a sustainable, versatile material, perfect for your most innovative projects.

We hope you found this post interesting. And as we always say: Be Smart!