NIT Rourkela Gets Patent for Extruder to Produce Composite 3D-Printing Filaments

The innovation could help reduce dependence on virgin plastic and promote the conversion of plastic waste into value-added products. Developed at a cost of around Rs 45,000, the system comprises an extruder, a controlled cooling system and PID temperature controllers, among other components, enabling precise control over the filament manufacturing process.

Three-dimensional printing is increasingly being used in biomedical and engineering applications, including the production of scaffolds, anatomical models, decorative items, brackets, drone components and toys. Fused Deposition Modeling (FDM), one of the most widely used 3D-printing technologies, works by melting thermoplastic filament and depositing it layer by layer to create an object.

However, commercially available thermoplastic filaments can be expensive, while low-quality filaments can compromise print quality and dimensional accuracy. Although researchers worldwide are exploring recycled plastics as a cheaper and more sustainable alternative, their wider use has been constrained by processing costs, material wastage, inadequate mechanical strength and limited durability.

The NIT Rourkela team has sought to address these challenges through its filament extrusion system, which can combine plastic particles with reinforcement materials to produce filaments with improved strength and durability.

"The developed filament extrusion system represents an advancement in filament production technology, offering compelling technical and commercial benefits for the 3D-printing industry. The composite filament produced through the developed extruder can be used for 3D printing of parts with improved mechanical properties desired for a wide range of applications. Further, the use of recycled plastic in making filament will offer substantial environmental benefits," said Prof. Sandhyarani Biswas, Associate Professor, Department of Mechanical Engineering, NIT Rourkela.

According to the researchers, laboratory-scale tests showed that the filaments produced using the system had satisfactory mechanical properties and the desired dimensional accuracy.

Prof. Sujit Sen, Professor, Department of Chemical Engineering, NIT Rourkela, said the system could convert various types of plastic waste into useful 3D-printer filament, creating a sustainable closed-loop system for recycling, reuse and remanufacturing.

The research team comprises Prof. Sandhyarani Biswas, Prof. Sujit Sen, Jagdish Uday Khatu, Himanshu Singh and Kiran Suna. The patent application for the extrusion system was filed under Application No. 202431068691 on July 30, 2026.

The composite filaments developed through the system could find applications where greater strength and durability are required, while also supporting more sustainable 3D-printing practices.