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XTRUDR/Plastic Bottle to 3D Filament

A compact, low-cost machine that recycles plastic bottles into usable 3D printer filament to promote sustainable manufacturing.

  • This is the overview of our design.

  • This video contains the instruction and how the XTRUDR machine works.

    This video contains the instruction and how the XTRUDR machine works.

  • First, use the air pump provided in the machine.

  • Heat the bottle using heat gun provided in the machine.

  • Set the suitable temperature according to your bottle types.

  • Step by step guidance instruction

What it does

The system transforms waste plastic bottles, particularly PET, into high-quality 3D printing filament through a series of mechanical and thermal processes.

Your inspiration

The idea stemmed from the growing concern about plastic waste, especially in Malaysia where recycling rates are low and PET bottles are among the most discarded items. The team was inspired by the potential of 3D printing as a sustainable manufacturing tool and sought to bridge these two domains by creating a solution that both recycles and empowers users to fabricate new items from plastic waste.

How it works

The system begins by cutting PET bottles into strips, which are then fed into a 3D printer hotend using a geared motor and gear-driven spool system. A consistent heating process softens the plastic, which is e motor for steady feeding, and a spool for collection. Power is supplied via a 12 V 20 A source, and 3D-printed gears ensure low-cost fabrication. The machine also features a mini pump to help expand crushed bottles before feeding.

Design process

1. Concept: Originated from brainstorming solutions to plastic waste. 2. Initial Prototype: Manually fed PET strips with basic extrusion. 3. Iteration 1: Integrated geared motor and spool for automated feeding. 4. Iteration 2: Added heat gun and hotend to achieve better extrusion quality. 5. Final Design: Compact body, AC heat gun, 12 V motor, pump, and spool-based system with 3D-printed parts. Improvements were made in cutter design, heating stability, and filament consistency after multiple testing cycles.

How it is different

1. Compact and affordable for household or student use. 2. Modular and partially 3D-printable. 3. Designed to operate with PET bottles specifically. 4. Easy to use with minimal technical knowledge. 5. Powered using commonly available components like 12 V motors and heating elements.

Future plans

1. Improve filament diameter control using sensors and auto-regulation. 2. Develop a mobile app for real-time temperature and speed monitoring. 3. Launch a commercial version for schools and makerspaces. 4. Expand to accept other plastics (like HDPE and PLA). 5. Collaborate with local recycling centers or fab labs.

Awards

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