How to Turn 3D Printing Waste into New Filament?

Turning 3D printing waste into new filament is a fantastic way to reduce plastic waste and save money. This process, known as filament recycling, involves collecting, processing, and extruding waste material into usable filament. Here's a step-by-step guide to help you get started:

Step 1: Collect and Sort Your Waste

● Types of Waste: Collect failed prints, support structures, and scraps. Ensure they
are clean and free of debris.
● Material Sorting: Separate waste by material type (e.g., PLA, ABS, PETG). Mixing
materials can result in poor-quality filament.
● Remove Contaminants: Clean off any adhesives, paint, or dirt from the waste.

Step 2: Shred the Waste into Small Pieces

● Shredding Machine: Use a plastic shredder or granulator to break down the waste
into small, uniform pieces (pellets or flakes).
● DIY Option: If you don’t have a shredder, you can manually cut the waste into small
pieces using heavy-duty scissors or a cutting tool.

Step 3: Dry the Shredded Material

● Why Dry? Moisture can degrade the quality of the filament during extrusion.
● How to Dry: Use a food dehydrator, oven, or filament dryer to dry the shredded
material at the appropriate temperature for the plastic type (e.g., 45–60°C for PLA).

Step 4: Extrude the Material into Filament

● Filament Extruder: Use a filament extruder machine (like the Filastruder or Felfil
Evo) to melt and extrude the shredded plastic into filament.
● Extrusion Process:
1. Load the dried plastic pellets into the extruder hopper.
2. Heat the extruder to the melting temperature of the material (e.g., 160–180°C
for PLA, 230–250°C for ABS).
3. Extrude the melted plastic through a nozzle to form a consistent filament
strand.
● Diameter Control: Use a filament winder or spooler to ensure the filament has a
consistent diameter (typically 1.75mm or 2.85mm).

Step 5: Spool and Store the Filament

● Spooling: Wind the extruded filament onto a spool using a manual or automated
winder.
● Storage: Store the recycled filament in a dry, airtight container with desiccant to
prevent moisture absorption.

Tools and Equipment Needed

1. Plastic Shredder/Granulator: To break down waste into small pieces.
2. Filament Extruder: To melt and extrude the plastic into filament.
3. Filament Winder: To spool the extruded filament.
4. Drying Equipment: Food dehydrator, oven, or filament dryer.
5. Calipers: To measure and ensure consistent filament diameter.

Challenges and Tips

● Material Degradation: Repeated recycling can weaken the plastic. Mix in some
virgin material to maintain strength.
● Consistency: Achieving a consistent filament diameter can be tricky. Practice and
calibration are key.
● Safety: Wear protective gear (gloves, mask, and goggles) when handling hot plastic
and machinery.

DIY vs. Commercial Solutions

● DIY: If you’re on a budget, you can build your own shredder and extruder using
open-source plans and kits.
● Commercial: For convenience, invest in a complete recycling system like the
ProtoCycler or Filabot.
Benefits of Recycling 3D Printing Waste
● Eco-Friendly: Reduces plastic waste and environmental impact.
● Cost-Effective: Saves money by reusing material.
● Custom Filament: Create unique colors and blends by mixing different waste
materials.

By recycling your 3D printing waste, you can contribute to a more sustainable 3D printing ecosystem. Let me know if you need help finding specific tools or resources!