As anyone with a 3D printer can tell you, printing doesn’t always go the way you plan for it to. Despite meticulous planning to account for possible issues, you are inevitably going to end up with some prototypes or misprints. These misprints can range from small, barely noticeable errors to complete project failures that make the entire print unusable. Over time, this leads to a growing pile of discarded prints, and for anyone invested in 3D printing, the question becomes: What do you do with all that waste? This was the problem we faced. We noticed that we were going through filament quickly, which not only meant a lot of plastic waste but also a significant expense, as filament can get pretty pricey.
In an effort to address this issue, we began looking for ways to reuse all of our unusable prints. After conducting some research, we learned that filament could be recycled and that many others in the 3D printing community were exploring solutions to this same problem. This realization sparked the beginning of our project. During our research, we found examples of people who had successfully built grinding systems to process discarded prints, and we decided to use one of these designs as the foundation for our own project. However, we wanted to take it further, creating a complete system that not only grinds old prints into reusable material but also transforms that material back into filament that could be used in 3D printers.
The project we envisioned has two distinct phases. The first phase involves building a grinding machine to crush old 3D prints into smaller, more uniform pieces. These pieces would serve as the raw material for the second phase. In phase two, we plan to build an extruder that will melt the crushed pieces and reshape them into new filament of the appropriate size for use in a 3D printer.
Getting started on the project was not without its challenges. One of the first obstacles we faced was that we lacked the tools and equipment necessary to cut and weld metal, which are crucial steps in building the grinding machine. To overcome this, we reached out to local businesses to see if they could help us fabricate the components we needed. Fortunately, we found several businesses that were not only capable but also willing to take on the task. These partners were able to take the plans we had found online and modify them to suit our specific requirements. They then cut and began welding the pieces together for us.
Phase one has been a long process. We have been working on this project for about two years, and while progress has been slower than we originally hoped, we have made significant strides. One of the reasons for the delay was the departure of the original student who initiated the project. This meant the project had to change hands, which took some time to coordinate. Additionally, acquiring the right materials has been an ongoing challenge, as some components were harder to source than we anticipated. Despite these setbacks, we are now close to completing the grinding machine.
So far, we have been able to laser-cut the metal pieces needed for the grinder, and we’ve successfully acquired a motor that will power the machine. One of our partners, NEATCT, has been instrumental in helping us weld the stand for the grinder. Once the stand is complete, which we anticipate will happen in the spring of 2025, we will focus on fine-tuning the machine to ensure it functions as intended. This step will involve testing the grinder with various types of discarded prints to see how well it processes the material and making adjustments as needed.
Once the grinding machine is fully operational, we will shift our focus to phase two: the extruder. This part of the project is just as ambitious as the first phase. The extruder will need to melt the crushed plastic pieces and reshape them into filament that is consistent in diameter and quality. This step is crucial because the usability of the recycled filament depends on its ability to match the specifications of commercially available filament. To achieve this, we’ll need to conduct extensive testing and make sure the extruder is calibrated correctly.
Beyond completing the project for our own use, we have bigger aspirations. We are already brainstorming plans to create a larger version of this system that could be used by industries outside of the 3D printing community. Many industries generate significant amounts of plastic waste, and a system like ours could help them grind that waste down and repurpose it for other applications. This could contribute to reducing the environmental impact of plastic waste on a much larger scale.
Our journey has been one of persistence and creativity, and although it has taken longer than we initially expected, we are proud of the progress we’ve made. The experience of designing and building something from scratch, overcoming challenges along the way, and working with local partners has been incredibly rewarding. We hope that when our project is finally complete, it will not only solve our own problem of filament waste but also serve as a model for others looking to reduce their plastic waste and embrace more sustainable practices in 3D printing and beyond.
In the meantime, we’re excited to see the grinder come to life and are already looking forward to starting work on the extruder. The spring of 2025 will mark an important milestone in our project, and we can’t wait to see how the finished grinding machine performs. With determination, collaboration, and a little bit of patience, we’re confident that we’ll achieve our goal of creating a fully functional recycling system for 3D printing filament.