Filament-Recycler

Project Description – Desktop Filament Recycling Machine

TGM Technologisches Gewerbemuseum, Vienna, Austria

Höhere Abteilung für Maschinenbau ~ Robotik & Smart Engineering

Diploma Thesis – Class of 2025/26

Motivation and Background

Our team of three students from the TGM in Vienna, Austria is developing a desktop filament recycling machine as part of our diploma thesis. As regular 3D‑printing users, we have experienced firsthand how quickly filament waste accumulates: failed prints, leftover ends of spools, and support structures that cannot be reused. Although these fragments are still valuable material, most users have no practical way to recycle them at home. This realization sparked the idea for our project. We wanted to create a compact machine that would allow individuals to transform their own plastic waste into new, high‑quality filament.

Technical Design and Development Tools

The design of the machine is fully developed in Autodesk Inventor Professional 2026. Throughout the project we combine mechanical engineering, electrical engineering, programming, and materials science. This interdisciplinary approach allows us to create a system that is technically robust, user‑friendly, and efficient. Our goal is not only to reduce environmental impact, but also to make 3D printing more affordable by giving users the ability to recycle their own material instead of constantly purchasing new spools.

Figure 1: Filament-Recycler

Recycling Process and Machine Functionality

The machine works by processing previously shredded PLA or PETG fragments. These small pieces are poured into a hopper, from which they are guided into a heated extrusion unit. At the core of the extrusion system lies our specially designed extruder screw, which is being produced by PCBWay along with several other essential components. It transports the material through the barrel, compressing and melting it until the plastic becomes a homogeneous melt. Afterward, the plastic is forced through a precision‑machined nozzle, forming a continuous filament with a defined diameter. Once it exits the nozzle, the filament passes through a cooling section that stabilizes it before being guided into an automated spool‑winding mechanism. This winder places the filament evenly onto a standard spool, ensuring that the final product is ready for immediate use in any FDM 3D printer.

Figure 2: Extrusion Screw

Team roles and responsibilities

Each team member plays an important role in this project. One of us focuses primarily on the extrusion assembly itself, which includes the extruder screw, the heating system, the nozzle interface, and the drive components. This part of the machine requires careful geometric design and an understanding of material flow and heat transfer. Another team member concentrates on the structural frame of the machine as well as the winding mechanism. They also carry out detailed thermal simulations using Inventor Nastran to study how heat spreads through the system and how sensitive components must be protected. The third member works closely on the winding mechanism while also being responsible for most of the electronic systems. This includes integrating sensors, designing control circuits, programming temperature regulation, and ensuring that the winding system operates smoothly and safely.

Figure 3: Melting Area

Collaboration with PCBWay

When searching for a manufacturing partner for the more complex components of our machine, we came across PCBWay. Their reputation for precision, reliability, and support for student initiatives convinced us immediately. For us as students, having access to high‑quality production services is essential, especially when dealing with custom mechanical parts and electronic boards. We are very grateful for the opportunity to apply for sponsorship and believe that PCBWay’s expertise would significantly enhance the quality and final presentation of our prototype. By working together, we hope to bring our recycling machine to a fully functional and professional level.