Picture: University of Colorado Boulder
At the College of Engineering and Applied Science at the University of Colorado Boulder, a program has been launched to turn plastic waste from the 3D printing process into new materials. The goal is to reduce the amount of unusable PLA waste while also providing materials for student projects. The initiative is part of the Integrated Teaching and Learning Program (ITLP) and is seen as a practical approach to sustainable engineering education.
The idea originated in a course when a team led by design engineering student Ian Mcleod explored ways to reuse failed prints and excess support structures. Together with ITLP engineer Kathryn Penzkover, the group developed a process that was later optimized by mechanical engineering student Eli Post. Today, the recycling method is firmly integrated into the ITLP workflow.
The recycling process involves several steps: failed PLA prints are collected, shredded, and then pressed into stable sheets using a heat press. These sheets can be used for laser-cutting projects, partially replacing the use of new raw materials. Students can use the recycled sheets free of charge, saving resources while encouraging creative applications.
Financial support came from the Engineering Excellence Fund, which enabled the purchase of an industrial shredder. This allowed plastic waste to be processed into uniform fragments, making the entire workflow more efficient. The concept has already been recognized on campus: the student team won both the first prize and the audience award at the 2025 Sustainability Summit. In addition, Post published a detailed guide so the approach can be replicated beyond the university.
“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,” said Kai Amey, director of engineering education and operations for the ITLP. “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.”
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