ReLO

Stage 1. Material Waste Observation

Began by looking at where material is lost in small labs and home printing setups: failed prints, purge material, support removal, and clog-related scrap. For hobbyists and small studios, a significant share of every spool ends up unusable, something I see firsthand prototyping with 3D printing in my own studio. Yet small-scale printing lacks cost-effective, closed-loop recycling options designed for home or micro-studio use.

Stage 2. System Strategy & Safety Framework

Developed a recycling strategy prioritizing safety, enclosure, and continuous throughput over industrial-sized shredders. Outlined a 4-module sealed workflow: shredding, heated softening, filament extrusion, and spool winding. Integrated HEPA filtration and micro-plastic containment to prevent airborne waste. The strategy established ReLO not just as a recycling tool, but as a safer and truly “desktop-scale” circular system.

Stage 3. Design Development

Functional Modules:
Designed slow-speed shredding with assisted softening to reduce jams, plus a dual-bearing pull extrusion stage intended to keep filament diameter consistent.

User Workflow:
Designed loading doors, thermal UI prompts, and post-processing guides so users can manage recycling the way they manage printing, without guesswork.

Safety by Design:
Micro-plastic sealing, exhaust routing, and heat-control tolerances are specified to desktop-appliance expectations rather than DIY machine norms. Physical safety testing is planned for a future prototype.