A team of engineering students at the University of Colorado (CU) Boulder has developed a new way to recycle 3D printing waste, transforming discarded plastic into reusable sheets for hands-on projects across campus. Now part of the College of Engineering and Applied Science’s Integrated Teaching and Learning Program (ITLP), the effort reflects a growing push to pair sustainability with innovation in engineering education.
“Incorporating recycled plastic into hands-on engineering education turns what would have been waste into a shared resource for students. By making these materials freely available, we are reducing our environmental impact while giving students new opportunities to innovate and create,” said Kai Amey, director of engineering education and operations for ITLP.
Turning Waste into Learning Materials
The idea began in an undergraduate classroom, where integrated design engineering major Ian McLeod and his team explored how to repurpose failed prints and excess support structures made from PLA filament. With guidance from ITLP engineer Kathryn Penzkover, the concept evolved into a functioning recycling process and was later refined by mechanical engineering student Eli Post, an ITLP summer intern.
Using a simple workflow, the team collects failed or excess PLA prints, grinds them into small fragments, and presses them into durable flat sheets with a T-shirt press. The resulting material can be laser-cut or used in other fabrication projects, giving students access to a free, sustainable alternative to traditional plastics.
The project’s impact has already been recognized on campus. The student team earned first place and the People’s Choice Award at the 2025 Campus Sustainability Summit, and Post published a step-by-step Instructible to help other universities and makerspaces replicate the system.
Funding from the Engineering Excellence Fund helped the group purchase a polymer shredder, allowing for more consistent processing of PLA waste and making the recycling process scalable within the ITLP.
“What excites me most about this project is that this started with students who saw a problem and decided to solve it. By backing their creativity with mentorship and resources, we are not only cutting down on waste, we are showing future engineers that they have the power to drive real change,” added Amey.
The ITLP plans to continue expanding its recycling and sustainability initiatives, integrating responsible resource management into its engineering education framework.
Recycling Efforts in Additive Manufacturing
Beyond initiatives at University of Colorado Boulder, the additive manufacturing industry is making significant strides in promoting sustainability and material recycling. In February, America Makes, and the National Center for Defense Manufacturing and Machining announced the winners of a $2.1 million funding round, covering six key research areas. Among these, ASTM International, a global standards organization, will lead a $600K project on Analysis of AM Sustainability and Environmental Benefits.
This project will focus on developing methodologies for reutilizing and recycling AM materials. It will explore strategies for material recovery, lifecycle assessments, and frameworks to help manufacturers adopt eco-friendly practices without compromising part performance or reliability. The research will build on ASTM’s expertise in AM standards, qualification, certification, and sustainability, ensuring that the findings contribute to industry-wide best practices and regulatory guidelines.
In 2024, AMAZEMET, a Warsaw-based company, unveiled its Powder2Powder (P2P) atomization system at Formnext 2024. The system enables efficient recycling metal powders and in-situ production of custom pre-alloy feedstock, advancing sustainable metal powder production for additive manufacturing.
Want to help shape the future of AM? Join the Expert Committee for our 2025 3DPI Awards, launching later this summer.
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Image featured shows recycled PLA fragments from 3D printing waste prepared for reuse in CU Boulder’s ITLP recycling program. Photo via CU Boulder.
