108: Upcycling 3D Printing Waste Utilizing Injection Molding (Multidisciplinary Team)

With the growing emphasis on innovation and hands-on learning, maker spaces have become increasingly popular. These spaces, equipped with tools like 3D printers, facilitate rapid prototyping and design iteration. However, this convenience comes at the cost of significant amounts of polylactic acid (PLA) 3D-printing filament waste. Although manufacturers market PLA as a greener, compostable alternative to petroleum-based plastics, it often fails to fulfill this promise. Classified as a type 7 plastic, most recycling programs don’t accept PLA and the substance doesn’t fully degrade outside industrial composting facilities. PLA isn’t recycled at Florida State University as part of the campus’s recycling program.

To address the PLA waste issue, we aimed to turn PLA scraps from on-campus 3D printers into upcycled products. We shredded the PLA, processed it in an injection molding system, and injected it into a customizable mold. We assessed the recycled PLA properties through mechanical, degradation, and rheological testing. We also evaluated factors such as ease of use and aesthetic quality to determine its suitability for beginners. Our results demonstrate that we could effectively mold recycled PLA for various products, offering a promising path toward greater sustainability in rapid prototyping environments.