Professor recognised for pioneering circular manufacturing methods

Professor Lucas Hof, a Mechanical Engineering professor at the École de technologie supérieure (ETS) in Montreal, has received the Mitacs Innovation Award for Outstanding Research Leadership. The award recognises Hof's contributions in advancing manufacturing processes through projects focused on automation, advanced materials, and sustainability.

The Mitacs Innovation Award for Outstanding Research Leadership recognises supervisors with strong records in industry partnerships, intern training, and impactful projects. Hof is one of 11 researchers selected for the Mitacs awards nationally. This year's awards span several categories, including research leadership, innovation, and start-up innovation.

Industry partnerships

Hof leads the Labouratory for Smart and Circular Manufacturing at ETS. Over the past six years, his research has involved more than 40 Mitacs interns. The team has worked with manufacturers ranging from start-ups to large enterprises, addressing practical industry challenges by implementing smart and eco-friendly solutions.

"Thanks to Mitacs, we're developing the next-generation systems and processes that Canadian manufacturers need as they transition to more circular production methods, closing the loop on energy and materials," said Hof. "We know we need to innovate more in Canada and train young people to become industry leaders of tomorrow, and the partnerships we forge with industry through Mitacs allow us to contribute to this."

Circular design

Among the projects led by Hof is a method for 3D printing recyclable shoes. The process alters the flexibility of a single material during printing, allowing shoes to be constructed with fewer parts and without glue. This design enables the sole to click into place, simplifying recycling and reducing waste.

"It's a beautiful example of a circular production method that changes the way we conceive a product," said Hof. The laboratory is currently in discussions with Canadian footwear manufacturers interested in adopting the technology.

In partnership with apparel research and innovation centre Vestechpro, Hof's team is addressing the issue of textile waste, projected to reach 134 million tonnes globally per year by 2030. The initiative involves mechanically recycling textiles into fibres, which are then turned into pellets. These pellets can serve as feedstock for manufacturing items such as 3D-printed or injection-moulded parts. The goal is to facilitate the production of new products from discarded clothing.

Smart safety systems

Working with CONFORMiT and Cascades, Hof's team is helping digitise industrial safety procedures. The project involves the development of a digital platform that models manufacturing processes and optimises lockout/tagout (LOTO) procedures by integrating IoT-enabled smart locks and geolocation. The system uses continuous feedback loops to adapt safety protocols, aiming to maintain safety while improving efficiency on the manufacturing floor. The solution is currently operating via Cascades' CONFORMiT.ai platform.

Additional projects

The laboratory is engaged in multiple projects with various organisations:

• Turbocam International: Development of high-precision machining processes for ultra-hard materials, targeting the aerospace sector.
• Cap Solar: Creation of smart systems for lightweight, flexible solar panels suited to curved surfaces.
• Siemens Energy Canada: Decarbonisation of gas turbine packaging using additive manufacturing and sustainable materials.
• Cadence Automation and Neurobot IA: Development of AI models for automated powder coating and robotics to address labour shortages.
• Edgehog Advanced Technologies: Advancement of low-cost, anti-reflective nano-structures for glass, improving solar panel efficiency.
• VPM Research: Creation of defect-free metal parts through an environmentally friendly 3D printing process.