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.
Mestri et al. (Wed,) studied this question.