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.

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.

Vertiv, a global provider of critical digital infrastructure, is supporting the expansion of the IIT Madras Pravartak Technologies Foundation data centre skilling initiative into Maharashtra through its corporate social responsibility programme. The initiative aims to prepare engineering students for careers in data centre operations, digital infrastructure management and AI-ready facilities.

As part of the expansion, IIT Madras Pravartak Technologies Foundation signed a Memorandum of Understanding with the Ratan Tata Maharashtra State Skills University (RTMSSU). The MoU was signed during the Start-up Frontier 1.0 exhibition and conference at the Y B Chavan Auditorium in Mumbai in the presence of Maharashtra Governor Shri Jishnu Dev Varma.

Training 1,500 students in 2026

Through the initiative, Vertiv will provide free skill development training to 1,500 engineering students during 2026. The programme builds on a collaboration launched in 2025 between Vertiv and IIT Madras Pravartak Technologies Foundation to strengthen India’s talent pipeline for the rapidly expanding digital infrastructure industry.

Vertiv’s expertise covers critical areas such as data centre infrastructure, thermal management, power systems, remote monitoring and predictive maintenance. These topics are essential for maintaining uptime and operational efficiency in always-on digital environments.

Maharashtra-wide academic reach

RTMSSU will use its network of pre-incubation centres across 60 colleges in Maharashtra to extend the programme’s reach. This network can help students from different regions access industry-oriented training without needing to relocate to major technology hubs.

Participants will receive certified online training, along with opportunities for internships and mentorship. The blended approach is expected to give students both foundational knowledge and practical exposure to workplace requirements. It can also help bridge the gap between conventional engineering curricula and the specialised skills demanded by the data centre sector.

Earlier versions of the initiative included self-paced online learning and immersive in-person training. The curriculum covered data centre operations and maintenance, thermal and power management, security, network systems, racks, power distribution units, ticketing tools and industry practices.

Preparing talent for AI growth

India’s rapid adoption of artificial intelligence is creating a parallel demand for reliable digital infrastructure. AI applications require large-scale computing capacity, energy-efficient cooling systems and uninterrupted power management. As data centres expand, companies will need professionals who understand both traditional facility operations and emerging intelligent monitoring technologies.

Dr. A. S. Prasad, Vice President, Product Management and Engineering, Vertiv India, said that collaboration between industry and academia is essential to build a skilled workforce. He added that practical knowledge, industry exposure and specialised training can help students contribute to India’s evolving digital infrastructure ecosystem.

Dr. M. J. Shankar Raman, Chief Executive Officer of IIT Madras Pravartak Technologies Foundation, noted that data centres are central to the growth of AI-driven industries. He said the programme aims to develop the technical talent required to operate and maintain these critical facilities.

Strengthening industry-academia collaboration

Vertiv has also partnered with IIT Bombay, IIT Madras Pravartak Technologies Foundation and IIT (BHU) to help engineering students develop practical skills in data centre operations and AI-ready infrastructure. The programme reflects a wider need for industry-backed education that combines certification, mentorship and real-world learning.

By expanding to Maharashtra, the Vertiv-IIT Madras initiative is creating a stronger national talent pipeline. It could improve student employability while helping India meet the workforce demands of its fast-growing cloud, AI and digital infrastructure economy.

FAQs

1. What is the Vertiv and IIT Madras data centre skilling programme?

 The programme is a skill development initiative supported by Vertiv and implemented with IIT Madras Pravartak Technologies Foundation to train engineering students in data centre operations, digital infrastructure management and AI-ready technologies.

2. How many students will receive training under the programme in 2026?

 The initiative aims to provide free data centre skill development training to 1,500 engineering students during 2026.

3. Who is partnering with IIT Madras Pravartak for the Maharashtra expansion?

 IIT Madras Pravartak Technologies Foundation has signed an MoU with Ratan Tata Maharashtra State Skills University (RTMSSU) to expand the programme across Maharashtra.

4. What topics will students learn in the data centre training programme?

 Students will learn about data centre operations and maintenance, power management, cooling and thermal systems, remote monitoring, predictive maintenance, IT infrastructure, network systems, racks, power distribution units, security and industry practices.

5. What benefits will students receive from the Vertiv-IIT Madras programme?

 Participants will receive certified online training, along with opportunities for internships, mentorship and practical industry exposure. The programme is designed to improve employability in data centres, cloud infrastructure and AI-ready digital infrastructure.