Modernizing manufacturing with circular design and AI

The challenge: Helping manufacturers compete in a changing global economy 

As Canadian manufacturers face rising costs, global competition, and increasing pressure to adopt sustainable practices, many are turning to automation, advanced materials, and circular production methods to remain competitive. Transitions like this require smarter and more sustainable manufacturing systems, as well as research expertise, technological innovation, and strong collaboration between academia and industry. 

There is a growing need for solutions that not only improve efficiency and reduce waste but also strengthen Canada’s productivity and global competitiveness. 

The solution: Building circular manufacturing systems 

Professor Lucas Hof, a Mechanical Engineering professor and director of the Laboratory for Smart and Circular Manufacturing at École de technologie supérieure (ETS), has spent the past six years working alongside more than 40 Mitacs interns to support manufacturers of all sizes — from start-ups to large enterprises — in developing practical, forward-looking solutions. 

Together, they are developing circular manufacturing models that rethink the design, production, and reuse of products. One example is a novel approach to 3D printing recyclable shoes using a single adaptable material, eliminating glued components, and allowing the sole to click into place. By reducing material complexity, the design makes recycling far more feasible.  

The lab is also working with partners to transform textile waste into usable manufacturing feedstock. By mechanically recycling old textiles into fibres and converting them into pellets for 3D printing and injection molding, the team is helping create new products from discarded clothing. 

Beyond circular materials, the research extends into intelligent industrial systems. In collaboration with CONFORMiT and Cascades, Hof’s team is developing a digital platform that models manufacturing processes and continuously optimizes lockout/tagout safety procedures. By integrating IoT-enabled smart locks, geolocation technologies, and real-time dashboards, the system improves safety while streamlining workflows. 

The outcome: Applied research to industrial transformation 

Through these collaborations, Canadian manufacturers are gaining access to advanced tools and technologies that improve efficiency, reduce waste, and modernize production processes. Student researchers are not only contributing to real-world industrial challenges but also gaining hands-on experience in deploying emerging technologies across sectors. 

“Thanks to Mitacs, we’re developing next-generation systems and processes that Canadian manufacturers need as they transition to more circular production methods,” said Hof. “The partnerships we build with industry allow us to innovate while training the leaders of tomorrow.” 

The work demonstrates how research-driven collaboration can directly strengthen Canada’s manufacturing ecosystem while supporting economic resilience and sustainability. 

Talent in action: Leadership that drives industry innovation 

For his sustained leadership in building impactful partnerships and mentoring student researchers, Professor Hof has received a Mitacs Innovation Award — Outstanding Research Leadership. The award recognizes post-secondary supervisors who foster strong industry collaborations and create meaningful training opportunities for emerging talent. 

He is one of 11 Mitacs award winners nationally, selected from thousands of participants in Mitacs programs each year. The awards were presented at a ceremony at the National Arts Centre in Ottawa on November 17.

About Mitacs  

For over 25 years, Mitacs has helped grow the economy and develop the workforce of tomorrow, connecting industry with academia and global partners to solve real-world challenges. We support business-academic research collaboration through internships, co-funded with businesses, for undergraduate to graduate students and post-doctoral fellows.   

As a national innovation connector, Mitacs takes a talent-first approach to strengthen innovation capacity and drive global competitiveness. We serve as an essential research-commercialization bridge, accelerating market entry and growth for new products and services.   

This is a critical time for Canada to think big and take bold action. Mitacs is ready to help build a strong and resilient Canadian economy, powered by ideas, talent and innovation.   

Mitacs is funded by the Government of Canada, the Government of Alberta, the Government of British Columbia, Research Manitoba, the Government of New Brunswick, the Government of Newfoundland and Labrador, the Government of Nova Scotia, the Government of Ontario, Innovation PEI, the Government of Quebec, the Government of Saskatchewan, and the Government of Yukon.