Disruptive design

An outside-the-box creative uses recycled plastic to 3D print aesthetic objects for home.

Words Casey Vassallo

Founder Matt Watkins.

Based in Tauranga, Special Studio is a design and production studio that fashions intriguing objects from recycled plastics using 3D printers. Located on Durham Street, the space acts as both the workshop and showroom, where each piece comes to life.

It kicked off with the Lulu bin in 2021, named after friend and designer Lulu Jackson (of Lulu Jackson Bridal), who suggested adding a twist to the prototype, literally. “The idea was to make a rubbish bin out of rubbish,” says founder Matt Watkins.

The first sale came through Instagram, and Mount Maunganui’s beloved Paper Plane became their first retailer. The business has since snowballed, and today, it can’t keep up with demand despite making around 100 pieces a week.

The distinct and popular Lulu form has gone on to become a display bowl, funky planter and stool, which remains their bestseller and takes up to 14 hours to print. More recently, they’ve added a bulbous Bubble side table to the repertoire, a stone-looking Monolithic side table, and a collection of mini Lulu stools for the little ones. There’s also a new rock collection, where no two objects turn out the same, and a range of lighting is in production.

Other designs have been born from collaboration, like the Twist side table by designers Daniel Vi Le (who works for the likes of Cult Gaia) and Tanil Raif (ex-Yeezy design architect), and can be found in the Orange County Museum of Art’s Please Do Not Enter concept store as Special Studio’s first international stockist. Matt has also worked with Warren and Mahoney Architects to engineer an e-waste recycling bin for One NZ’s stores nationwide, featuring the Noise design’s rippled texture and embossed with “recycled devices”.

Matt puts Special Studio’s success down to the unison between the designs and materials, similar to Tesla’s recipe. “Our products could look this great, but if they weren’t made from recycled plastic, they wouldn’t sell as well,” he explains. “If they were all made from recycled plastic, but they didn’t look this good, we wouldn’t sell them.”

Back when Matt bought his first 3D printer in 2018, it didn’t start with what to make, but how. More specifically, mass production’s unsustainable nature spurred him to create his own circularity model.

“The goal for starting the company was to figure out the best way to make stuff, period,” Matt says. “You need to make on demand, and that’s what led to get into additive manufacturing and 3D printing.” That is, 100 machines making 100 objects are more reliable and adaptable than one machine making 100 objects.

Running close to 24/7, Special Studio has a host of small Delta 3D printers and a few custom-made large-format printers of their creation. “We make what we sell, which is incredibly rare,” Matt says.

“And because we make the machines that make the products, we have total control over the production process.”

It’s also Matt’s way of looking at a global issue – plastic waste – and how he can spin it into a solution. “The problem with plastic is behavioural. We have to stop using plastics for single-use applications, but we shouldn't demonise plastic,” he says. “It’s easier to recycle, easier to process, you can mould plastic, and it requires low energy.”

In its raw form, recycled plastic filament looks like fishing wire. Matt sources the colourful matte material from Netherlands company Reflow, and KiwiFil supply the clear, white, black and amber materials. Computer-operated, the 3D printer draws each design in fine layers using the filament. “The best way to explain it is a hot glue gun on the end of a robot,” Matt says. Close up, you can see the moulded lines that give each piece a textural look.

This isn’t Matt’s first successful venture, either. Off the back of DJing around town, he co-founded SoundSwitch in 2011, a software and hardware system used to synchronise lighting and music performances. He built the business from zero, raised capital, and learned the manufacturing game before selling to American enterprise inMusic in 2018.

Special Studio is soon looking to scale and set up 3D printers overseas (like the US and Australia) to make objects closer to their destination, but the Bay of Plenty will remain home. “If we had a machine in every major market, we could send the print files, and overnight it could be released globally,” Matt says.

Matt has always had a bigger picture in mind, though. “The long-term goal, whether that’s with Special Studio or a secondary company, is to move into functional architecture components,” he says of staircases, boats and homes. “For me it’s about design – being able to create something totally unique and new. That’s the exciting part.”