AUKUS Forum News feature story

AUKUS Forum News has just published a feature story about UNSW SMaRT Centre's pioneering recycling and remanufacturing MICROfactorie^TM Technologies.

Read the story as published - see pages 6 and 7

MICROfactories: Compact Powerhouses for Defence and Sustainability

MICROfactories redefine traditional manufacturing by compressing processes into small, modular systems capable of operating in diverse environments. These innovative facilities utilise locally sourced and recycled materials, aligning with sustainability goals while reducing reliance on global supply chains—a crucial factor in maintaining defence readiness. Their modularity allows for deployment near end-use locations, enabling rapid production and minimising logistical challenges.

In the context of AUKUS, MICROfactories offer decentralised production capabilities that complement distributed defence strategies. Embedding these facilities in bases or regional defence hubs can significantly enhance the ability to produce mission-critical components on demand, mitigating risks associated with supply chain disruptions during periods of geopolitical tension.

Transforming Waste into Resources: The Role of Material Science

The success of MICROfactories hinges on advanced material science and engineering. Transforming waste into high-performance materials requires a deep understanding of material properties, innovative recycling techniques, and sophisticated processing methods. Professor Veena Sahajwalla and her team at the UNSW SMaRT Centre are leaders in this field, pioneering technologies that convert waste into valuable industrial inputs.

One notable example is the Filament Microfactory, which processes plastics from discarded electronics (e-waste) to produce high-quality materials for additive manufacturing and other applications. These technologies illustrate how material science enables waste to become a critical resource, advancing both sustainability and industrial capability.

Advancing Innovation from Lab to Pilot Scale

The AUKUS partnership creates a unique opportunity to accelerate the commercialisation of transformative technologies through collaboration between research, defence, and industry. An example of this is the possibility of QPQ surface modification, developed at UNSW, which enhances the wear resistance and durability of steels using environmentally friendly methods. This innovation is particularly suited for defence applications such as naval and aerospace components, where materials must endure extreme operational conditions.

Scaling such technologies from lab to pilot requires coordinated efforts to overcome challenges related to infrastructure, regulatory compliance, and resource mobilisation. AUKUS can play a key role in establishing shared pilot facilities where these materials and processes can be tested under real-world conditions, ensuring they meet the operational standards of all partner nations. This approach not only accelerates technological maturity but also strengthens sovereign manufacturing capabilities.

Strengthening Supply Chains with Microrecycling and MICROfactories

Defence supply chains often rely on complex global networks, making them vulnerable to disruptions. MICROfactories address these challenges by enabling localised and decentralised manufacturing. By incorporating Microrecycling Science, developed at UNSW SMaRT Centre, they recover critical materials from waste streams and reintroduce them into production, reducing reliance on international supply chains and enhancing resilience.

Locally sourced waste materials are transformed into high-value outputs, creating a circular economy while supporting defence readiness. This capability allows MICROfactories to produce essential parts and materials near deployment sites, minimising logistical delays and ensuring that critical components are available when needed. For the Navy, this flexibility is invaluable in maintaining operational capabilities with minimal supply chain vulnerabilities.

Creating Economies of Purpose

MICROfactories extend their impact beyond defence by fostering "economies of purpose," which align technological innovation with societal benefits. By localising production and employing advanced recycling techniques, MICROfactories not only meet defence requirements but also generate jobs, upskill workers, and build sustainable manufacturing ecosystems in the regions. The production of recycled materials, such as e-waste-derived 3D printing filament, demonstrates how MICROfactories bridge the needs of defence with broader community development goals.

Conclusion

Powered by cutting-edge material science and Microrecycling innovations, MICROfactories offer a sustainable, decentralised manufacturing solution that can strengthen defence supply chains, supports operational readiness, and benefits local communities. Their integration into defence strategies can improve resilience and sustainability while contributing to broader societal goals.