The ₹45,000 portable system could make sustainable 3D printing more affordable for industry, healthcare and education
Researchers at the National Institute of Technology Rourkela (NIT Rourkela) have patented a low-cost and portable filament extrusion system that can convert recycled plastic waste into usable material for 3D printing. The innovation could reduce dependence on virgin plastic, lower filament production costs and support a more sustainable future for additive manufacturing.
The technology has been developed by Prof. Sandhyarani Biswas, Prof. Sujit Sen, Mr. Jagdish Uday Khatu, Mr. Himanshu Singh and Mr. Kiran Suna. The team secured the patent for the extrusion system under Application No. 202431068691, dated 30 July 2026.
Why 3D printing needs better filament
Three-dimensional printing is now used in several sectors, including healthcare, engineering, aerospace, education and consumer product design. Applications range from manufacturing anatomical models and medical scaffolds to producing brackets, drone components, toys and decorative objects.
The most widely used method is Fused Deposition Modeling (FDM). In this process, thermoplastic filament acts like the “ink” of a 3D printer. The filament is heated until it melts and is deposited layer by layer to create a finished product.
Most commercially available filaments are manufactured using virgin plastics and can be expensive. Low-quality filament can also cause irregular extrusion, poor print strength, dimensional inaccuracies and inconsistent surface finish. Although recycled filament offers an attractive alternative, its wider adoption has been restricted by processing costs, material wastage, inadequate mechanical strength and limited durability.
A portable recycling solution
NIT Rourkela’s patented system is designed to address these limitations through a compact and affordable extrusion setup costing approximately ₹45,000. The system includes an extruder, heating arrangement, controlled cooling mechanism and PID temperature controllers to maintain accurate processing conditions.
The system can melt plastic particles and push the material through a nozzle to produce filament. A cooling mechanism and water bath help solidify the extruded material, while a controlled puller maintains a uniform filament diameter. A diameter sensor can provide real-time feedback and adjust the pulling speed to ensure compatibility with standard 3D printers.
An important feature is the ability to combine recycled plastic particles with reinforcement materials. This allows the team to produce composite filaments with improved strength and durability rather than relying on recycled plastic alone.
Wide-ranging applications
Laboratory tests showed that the developed filaments had satisfactory mechanical properties and desired dimensional accuracy.
The material could potentially be used to create:
- Automotive, aerospace and electronics components.
- Consumer products and customised industrial parts.
- Educational and research prototypes.
- Dental models and medical scaffolds.
- Patient-specific prosthetics and orthotic components.
- Drone parts, brackets and functional tools.
Prof. Sandhyarani Biswas said the system offers technical and commercial benefits while delivering environmental advantages through the use of recycled plastic.
Supporting a circular economy
Prof. Sujit Sen described the technology as a step towards a sustainable closed-loop system in which plastic waste can be recycled, reused and remanufactured into value-added products. This approach can reduce the amount of plastic sent to landfills and decrease the environmental impact associated with producing new polymers.
The innovation could be particularly useful for universities, small workshops, makerspaces and research institutions that want to produce their own filament at a lower cost. By making recycled 3D printing material more accessible, the NIT Rourkela extruder has the potential to support both affordable manufacturing and environmentally responsible innovation.
Reducing the cost of 3D printing
One of the biggest advantages of the patented system is its relatively low cost. At approximately ₹45,000, the portable extrusion setup could provide an affordable alternative for institutions and small-scale manufacturers that may not have the budget for expensive filament-production equipment.
Instead of purchasing ready-made filament for every project, users could process suitable plastic waste and manufacture filament according to their requirements. This could help reduce material expenses, particularly in laboratories, engineering colleges, prototyping centres and makerspaces where 3D printing is frequently used.
Conclusion
NIT Rourkela’s patented low-cost filament extrusion system represents a promising step towards making sustainable 3D printing more affordable and accessible. By converting recycled plastic waste into usable 3D printing filament, the ₹45,000 portable system can help reduce plastic waste, lower material costs and decrease dependence on virgin plastics. Its potential applications across education, healthcare, research and industry make it a practical solution for supporting a more sustainable and circular approach to additive manufacturing.
FAQs
1. What has NIT Rourkela developed for recycling plastic waste?
Researchers at NIT Rourkela have developed and patented a low-cost portable filament extrusion system that converts recycled plastic waste into filament suitable for 3D printing.
2. How much does the NIT Rourkela filament extrusion system cost?
The portable extrusion setup costs approximately ₹45,000, making it potentially suitable for universities, research laboratories, makerspaces and small manufacturing facilities.
3. How does the NIT Rourkela plastic recycling extruder work?
The system melts plastic particles and pushes the molten material through a nozzle to form filament. A controlled cooling system, water bath, puller and diameter sensor help maintain a consistent filament diameter suitable for standard 3D printers.
4. Can the system produce stronger recycled 3D printing filament?
Yes. The system can combine recycled plastic particles with reinforcement materials to produce composite filaments with improved mechanical strength and durability.
5. What are the applications of the recycled 3D printing filament?
The filament can potentially be used for automotive and aerospace components, electronics parts, prototypes, consumer products, dental models, medical scaffolds, prosthetics, orthotic components, drone parts, brackets and functional tools.