AutoFill Reclaimer System for Recycling Thermoplastics into 3D Printing Filament

The Autofill Reclaimer System is an automated recycling solution that turns waste thermoplastic materials into reusable 3D printing filament. The system combines mechanical, electrical, and control components. It features a 3 HP three-phase induction motor with a gearbox, a PID-controlled heater assembly, and a thermocouple-based feedback system for precise temperature control. Waste plastic goes into the extruder barrel, where it melts, mixes, and is pushed through a nozzle to create continuous filament. The molten filament cools, gets tensioned, and is spooled using a coordinated winding mechanism. Experimental results show a consistent filament diameter of 1.75 ± 0.05 mm, stable extrusion between 200°C and 230°C, and low power consumption of 3 kWh per batch. The system achieved a yield efficiency of 90 to 92% with a smooth filament surface suitable for FDM 3D printing. By cutting filament production costs by up to 50%, the Autofill Reclaimer System supports sustainable manufacturing and aligns with circular economy principles in additive manufacturing. This work helps develop affordable, energy-efficient, and eco-friendly recycling solutions for educational, research, and small-scale industrial uses.