How To Get Started Using Recycled Filament For 3D Printing

3D Printing with Recycled Filament: A Guide to Sustainable Innovation

The world of 3D printing has come a long way since its inception. What started as a niche technology for prototyping and industrial applications has now become a widespread tool used by hobbyists, designers, and engineers alike. Alongside this expansion, the sustainability of the materials used in 3D printing has become a growing concern, 3d printing creates a lot of waste from supports to failed prints. As plastic waste from all forms of life continues to create environmental challenges, the concept of using recycled plastic in 3D printing is a promising way to mitigate the problem until a permanent solution to plastic waste production can be found.

In this post, we will explore how you can 3D print with recycled plastic, whether you purchase pre-made recycled filament or take things into your own hands by extruding your own filament using a Filastruder or a PullStruder. Let’s dive into the various methods, equipment, and benefits of this eco-friendly approach.

Why Use Recycled Filament for 3D Printing?

Currently, the most common materials used in 3D printing, such as PLA (polylactic acid) and ABS (acrylonitrile butadiene styrene), are derived from non-renewable resources. These materials contribute to plastic pollution and the depletion of natural resources.

By utilizing recycled plastics, you’re not only reducing the demand for virgin plastic but also helping to divert waste from landfills, incinerators, and oceans. Furthermore, recycling plastic can lower the carbon footprint of the printing process, making it a more sustainable process.

So What Are My Options For 3D Printing With Recycled Plastic?

If you are interested in reducing your plastic consumption using 3D printing, currently there are 3 viable options for you. Those are buying recycled filament, extruding your own using a Filastruder or a similar machine, or developing your own PullStruder system.

Buying Recycled Filament

For those who prefer a simpler approach to 3D printing with recycled plastic, purchasing pre-made recycled filament is the most straightforward option. Several companies are now producing high-quality filament made from recycled plastics, including PETG (recycled polyethylene terephthalate), PLA, and ABS. This filament is often sourced from consumer plastic waste, such as water bottles, food containers, and post-industrial waste, and also support material and failed previous prints coming from print farms.

Advantages of Buying Recycled Filament

1. Convenience: No need for specialized equipment or time-consuming processes. Simply purchase the filament, load it into your 3D printer, and begin printing.
2. Quality: Recycled filaments, especially those from reputable manufacturers, are designed to offer similar or even superior quality to virgin filaments. I would not say they have gotten there yet, but it is closer than the filament you would be creating using the following two methods.
3. Consistency: Buying from well-established brands ensures that the recycled filament meets the necessary specifications, like diameter tolerance and consistency, making it easier to achieve a smooth print.
4. Variety: Many manufacturers offer recycled filament in a variety of colors and materials, so you don’t have to sacrifice aesthetics or functionality when going green.

Challenges with Pre-made Recycled Filament

1. Cost: Recycled filaments are often more expensive than their virgin counterparts, although this gap is shrinking as demand for sustainable options rises.
2. Availability: Not all types of filament are available in recycled variants, so you may face limitations depending on your printing needs.
3. Strength: Current recycled filament options are getting close to virgin plastic filament, but you should still lower your expectations for quality, and strength.
4. Fulfillment: When you purchase recycled filament you don’t get the satisfaction of seeing your personal plastic waste footprint decrease, only your net. And you can’t see what plastics are exactly being recycled into this filament.

Extruding Your Own Filament Using a Filastruder

For those who are interested in getting hands-on and creating their own recycled filament, using a Filastruder is an excellent option to start. The Filastruder is a machine that allows you to recycle plastic waste into filament that can be used for 3D printing. It works by melting plastic waste and extruding it into filament that can be spooled and used on your 3D printer. Other similar machines out there work the same as the Filastruder, but it is better to get over the learning curve on the Filastruder than be amazed by the quality difference coming from a more expensive machine like the filabot. If you are interested in learning more about the Filastruder click here!

How Does a Filastruder Work?

1. Shredding: First, plastic waste (such as old bottles, failed prints, or discarded plastic items) is shredded into small pieces, this step must be done separately from the Filastruder, I cut a large hole in the top of an old paper shredder to do this. The more uniform the size of the plastic pieces, the easier it is for the Filastruder to process them.
2. Melting: The shredded plastic is then fed into the Filastruder’s extruder, where it’s heated to a specific temperature. This process melts the plastic into a more fluid form.
3. Extruding: Once melted, the plastic is pushed through a nozzle, forming a continuous strand of filament.
4. Cooling and Spooling: As the filament exits the extruder, it is cooled using a fan or water bath before being wound onto a spool for future use. The filawinder (sold separately) is often used for consistent spooling and can help with filament diameter consistency.

Advantages of Using a Filastruder

1. Customization: By extruding your own filament, you have full control over the type of plastic you use, the diameter of the filament, and the overall quality. You can experiment with different blends of plastics to achieve unique material properties.
2. Cost Savings: Although the initial cost of the Filastruder can be high, it can save you money in the long run, especially if you have access to large amounts of plastic waste.
3. Sustainability: Creating your own filament from recycled materials reduces waste and helps you reduce your carbon footprint.
4. Endless Materials: You’re not limited to pre-made recycled filament options. You can recycle virtually any plastic, including failed prints or items that otherwise couldn’t be recycled. I spent a lot of time experimenting with HDPE plastic from milk jugs.

Challenges with Filastruder

1. Time-Consuming: The extrusion process can take time, especially if you are creating filament in bulk. It may not be the fastest method for high-volume printing. When you get to the point where you think you’ve conquered the Filastruder, I recommend upgrading to a higher-quality machine like the filabot. You will see an increase in quality and a decrease in time.
2. Learning Curve: There’s a bit of a learning curve involved in setting up and calibrating the Filastruder for optimal filament quality. Even with all the time I’ve spent with the Filastruder my machine could still use some tuning.
3. Filament Quality: The quality of the filament depends heavily on the consistency of the plastic waste you use. Contaminants or mixed plastics can lead to inconsistent extrusion or poor-quality filament.

Utilizing a PullStruder for Smooth Extrusion

An alternative to the Filastruder is the PullStruder, which is a more advanced and efficient system for extruding filament from recycled plastic. If you want to recycle your own plastic at home the PullStruder is what I would suggest. It is far simpler than the Filastruder. While the Filastruder uses a direct extrusion method, the PullStruder uses a unique design where a motorized system pulls the filament through a heated extruder, allowing for more consistent output. The PullStuder has gained a lot of popularity recently.

How Does the PullStruder Work?

The PullStruder is a more specialized tool designed to give you greater control over the extrusion process. You start by stripping PET bottles into an approximately 5mm wide coil and then feed the plastic into an extruder. The PullStruder uses a motor and gears to pull the coil through the extruder. This results in a smoother, more uniform filament that is easier to use in your 3D printer. If you are interested in learning more about the PullStruder click here!

Advantages of Using a PullStruder

1. Consistency: The PullStruder’s system is designed to maintain a more consistent filament diameter, which can be a challenge when manually extruding with the Filastruder.
2. Higher Quality: The extruder’s technology often leads to cleaner filament, reducing the chances of clogs or print failures due to filament inconsistencies.
3. Initial Investment: Like the Filastruder, the PullStruder requires a considerable initial investment, if you are buying it prebuilt. However, the STL files for a basic Pullstruder are very easy to find on any open-source 3d printing file website, like Thingiverse. There are only a few things that you need to purchase like a motor and bolts if you assemble it yourself, making the Pullstruder a very affordable option.

Challenges with PullStruder

1. Setup: The setup and calibration of a PullStruder can be complex, and it may require additional expertise to get it running smoothly, however, it is still a much simpler setup than the Filastruder requires.
2. Length of Filament: There is additional melting required which can be a bit tricky if you want a long line of filament, that is more than just one plastic bottle.

Final Thoughts

3D printing with recycled plastic is a powerful way to reduce waste and contribute to sustainability in the 3D printing community. Whether you choose to buy pre-made recycled filament, use a PullStruder to extrude your own, or go with a more advanced Filastruder setup, you are making an important step toward reducing the environmental impact that comes from normal 3D printing waste. Especially now while the technology for recycled plastic filament is still developing.

By integrating recycled plastic into your 3D printing process, you not only contribute to a more sustainable future but also unlock new opportunities for innovation and creativity. As technology continues to improve, it’s exciting to think about the future of 3D printing with recycled plastics—and the role you can play in it.