Three Years of Research: What Have We Learned About 3D Printing with Recycled Plastics?

When we began working on the development of large-format robotic 3D printing using recycled plastics three years ago, we had a simple question: Can waste become a high-quality material for architecture and design?

Today, we know the answer.

Yes. But the path to that answer was much more complicated than we had originally imagined.

Supported by the Technology Agency of the Czech Republic, this project allowed us to integrate materials research, in-house technology development, robotic 3D printing, and new product design. Instead of a single innovation, an entire ecosystem emerged: an integration of materials research, robotic technology, software, and product development.

3D printing up to 180 cm

It’s not enough to just build a printer

Large-format 3D printing with recycled plastics isn’t just about melting and printing the plastic.

During the project, we discovered that just as important as the extruder’s design itself are the material’s properties, its preparation, moisture content, particle size, cooling, and how the entire technology is controlled.

That’s why, in addition to developing a new print head, we also devoted a large part of the project to materials research. We tested various types of recycled polymers, sought stable sources of waste materials, and verified their behavior during robotic printing. It turned out, for example, that industrial production waste is a much higher-quality source than ordinary mixed municipal plastics.

The result is not just the technology itself. We have also built up the know-how to work with these materials.

Brightened vs. unbrightened material

Products as Part of the Research

Every product created during the project was also an experiment.

With the Glimmers collection, we explored the limits of subtle geometries and the interplay of light.

With the Sediment collection, we tested recycled PLA and the possibilities of modular furniture.

The Elpida screen, the Glimmers light installation for the church in Lišany, the Reflexe collection for Designblok 2026, and the Grove modular planters represent the next step—testing the technology in real-world projects.

So it wasn’t just about design. Each project pushed the technology forward.

Digital manufacturing doesn’t end with printing

The project also included the development of our own software for preparing robotic printing and a digital eco-catalog.

In the final phase, we introduced the first parametric product configurator, Task.One, which allows users to modify a product’s geometry directly on the web and links digital design with future production.

This is the first step toward enabling customers to design a product exactly according to their needs, without having to create a new model from scratch every time.

Technology Ready for Further Development

The project has resulted in a functional prototype technology for large-format robotic 3D printing using recycled plastics, proprietary software for production preparation, a digital platform, a patent application, and a portfolio of products on which the technology has been validated.

For us, however, the end of the project does not mark the end of development.

On the contrary.

Now the next phase begins—translating the research results into everyday practice. We’re continuing to develop the technology, preparing new projects, and seeking partners who want to work with us to push the boundaries of circular manufacturing, robotics, and contemporary design.

Thank you

This project would not have been possible without the collaboration of a wide range of people and organizations.

We thank the Technology Agency of the Czech Republic for supporting project FW09020011—Development of Large-Format 3D Printing from Recycled Plastics and Its Commercial Applications in Innovative Eco-Design.

We would also like to thank our partners from the Faculty of Architecture at the Czech Technical University in Prague, as well as all the researchers, designers, technologists, students, industry partners, and collaborating organizations who participated in testing materials, developing the technology, and validating the results in practice throughout the project.

But our greatest thanks go to the entire Plastenco team. Over the past three years, we’ve created much more than just a new method of 3D printing. We’ve laid the foundation for a technology that demonstrates that waste plastic can be a fully-fledged material for architecture, design, and future circular manufacturing.

The Plastenco and FA CTU Research Team