Closing the Loop: How to Create a Sustainable Additive Manufacturing Process with Plastic Recycling

Additive manufacturing is revolutionizing how we create and innovate, but like any process, it comes with challenges—especially when it comes to waste. If you’re an avid 3D print user, an educator shaping the minds of tomorrow, or a material science professional pushing the limits of innovation, here’s a truth you can’t ignore: waste doesn’t have to be the end of the story.

At Filabot, we believe there’s a better way. We were founded on that belief!  You don’t just have to live with the scraps, failed prints, and leftover material piling up around you. You can turn them into opportunities. Let’s talk about how you can close the loop in additive manufacturing—transforming waste into high-quality filament and even compounding custom materials—to save money, reduce environmental impact, and open doors to new possibilities.

The Problem: Waste Is a Big Deal in 3D Printing

Let’s face it: 3D printing can create a lot of waste. Failed prints, support structures, and excess material all add up. For makers and educators running print after print, the waste can become overwhelming—both for your workspace and your wallet. And if you’re working with advanced or expensive materials, tossing those scraps feels even worse.

But here’s the thing: what if that waste didn’t have to be, well, waste? What if you could turn it into new filament and keep your projects rolling without skipping a beat? That’s where closing the loop comes in.

The Solution: Recycling and Custom Material Compounding

At Filabot, we’ve made it easy to recycle and reuse your 3D printing waste. Here’s how you can take control of your process and start creating a sustainable workflow:

1. Collect and Prep Your Waste: Start by gathering your failed prints, support structures, or raw plastic scraps. For educators, this might mean organizing a collection system in the classroom. For pros, it could mean rethinking how you handle prototypes and excess material.
   

2. Shred It Down: Use a shredder to break down the waste into small, manageable pieces. This step is crucial for creating consistency in the extrusion process.  We offer two types of shredders depending on your needs.  Our standard Reclaimer is a two-stage shredder best used for small projects.  The Industrial Reclaimer can be used for larger projects, but requires 3-phase power. 
   

3. Extrude New Filament: With Filabot’s extruders, like the EX2, EX6,or EX6 Industrial you can turn those shredded scraps into high-quality filament ready for your next project. Whether you’re working with PLA, ABS, PETG, or advanced materials like TPU, our systems make it easy.
   

4. Customize Your Filament: Here’s where the magic really happens. By compounding your recycled material with additives, fillers, or colorants, you can create filament that’s tailored to your specific needs. Need extra strength? Add carbon fiber. The possibilities are endless.

To help you find the best solution for your needs, we offer all the needed equipment individually, or as a bundle, and you can always schedule a call where we’ll help you find the best solution for your needs. 

Why Closing the Loop Matters

For Avid 3D Print Users:

• Save Money: Stop buying spool after spool of filament and start making your own. Recycling saves you cash and gives you more control.

• Get Creative: Imagine the freedom to create custom filament that’s perfectly suited to your project. With material compounding, you’re not limited to what’s on the shelf.

• Lead by Example: By recycling, you’re not just printing; you’re showing the maker community that sustainability is possible and practical.

For Educators:

• Teach Sustainability: Give students hands-on experience with recycling and extrusion, showing them how their choices impact the environment.

• Stretch Budgets: Instead of buying new filament, recycle classroom waste and reinvest that money into other resources.

• Inspire Innovation: Encourage students to explore material science and discover what’s possible with custom filament compounding.

For Material Science Pros:

• Explore New Frontiers: Test advanced materials and additives to create groundbreaking solutions.

• Drive Innovation: Develop new formulations and push the boundaries of what’s possible in additive manufacturing.

• Show Leadership: Be at the forefront of sustainable practices in the industry.

Tips to Get Started

1. Know Your Materials: Every plastic is different. PLA is easy to recycle and biodegradable, while PETG offers strength and durability. Understand what you’re working with to get the best results.

2. Experiment with Additives: Whether you’re adding color, strength, or conductivity, material compounding lets you unlock new capabilities in your filament.

3. Monitor Quality: Keep an eye on extrusion consistency to ensure your filament prints perfectly every time.

4. Share Your Success: Whether it’s in a classroom, online community, or professional network, your story can inspire others to embrace sustainable practices.

Closing the Loop: The Future of 3D Printing

Recycling and material compounding aren’t just nice-to-haves; they’re the future of additive manufacturing. By closing the loop, you’re reducing waste, cutting costs, and unlocking new creative possibilities.

At Filabot, we’re here to help you make it happen. Whether you’re a maker, an educator, or an innovator, we have the tools and expertise to help you take the next step. Ready to join the movement? Explore our recycling systems and see how you can create a more sustainable tomorrow, one filament at a time. Still not sure, schedule a call.  We’re here to help!