How to create sheets with filament spools

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While 3D printing itself may not generate waste, one of the by-products of production are the spools. After years of accumulating spools, we've successfully recycled a key waste product from 3D printing that used to end up in the trash. For each sheet, 34 spools are given new life, making them suitable for use in various applications, including furniture, product design and other amazing ideas.

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Table of Contents

  1. 1

    Shredding coils

    The first step consists of dividing the coils by material type, usually PP and PS, and shredding them. In this case with an industrial shredder, which achieves a uniform texture of approximately 5 mm per particle.

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  2. 2

    Mounting the plate

    The next step is to assemble the mould. For this purpose, a thin sheet of metal greased with natural wax is placed in the mould. This is followed by a structure of the desired shape and width. In this case the mould is 60 x 60 cm square and has a thickness of 2 cm. In this case the amount of material used is 8 kg.

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  3. 3

    Heating the plate

    Once the material is inside, it is covered with another sheet of metal to prevent it from sticking to the press, which is also waxed. Finally, the press is turned on and heated at 230ºC for 45m or until the plastic starts to overflow. Once the 45 min are over, until it cools down.

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3D printing waste reduction through spool repurposing involves industrial tools and custom fabrication processes. Below are the key components required for transforming plastic spools into sheets for design applications.

Tools

  • Material sorting system (for PP, PS, and other plastics)
  • Precision measurement tools (for 5 mm particle uniformity checks)
  • Thermal control devices (for monitoring 230°C/446°F temperatures)
  • Wax application equipment (for metal sheet coating)
  • Cooling timers (for post-press hardening)

Hardware

Consumables

  • 8 kg plastic spool material per sheet
  • Natural wax release agent
  • Heat-resistant mold seals
  • Protective gloves (for 230°C operations)
  • Insulation materials (thermal process safety)

All listed equipment can be sourced from industrial suppliers in Madrid like ~~Hercort~~ for shredders or ~~Tecni-Molde~~ for custom molds.

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