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Pultrusion and Extrusion to Recycle Filament

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Benjamin Davis · Wrentham, Massachusetts
Regeneron Young Scientist Award ($75,000) · Regeneron International Science and Engineering Fair · 2025

Abstract

A desktop machine that combines pultrusion and extrusion to turn 3D-printer waste back into usable filament, aimed at makerspaces and classrooms rather than industrial recyclers.

What they found
The result, in the terms the project itself reported it.

Reported about 45% greater efficiency than comparable systems at roughly 90% lower cost.

Why it worked
ResearchForge's reading of the public record — not the students' words, and not the judges' reasoning.

Combining two established processes rather than inventing one is an underrated engineering move, and the efficiency-versus-cost pairing is the argument for it. The target user is named, which keeps the cost figure meaningful.

Key methods
  • Pultrusion process design
  • Extrusion process design
  • Recycled filament quality testing
  • Efficiency and cost benchmarking
What to take from this
ResearchForge's reading of the public record — not the students' words, and not the judges' reasoning. Borrow the habits and decisions, never the project itself.
  • Two known processes combined can be a genuine contribution — say clearly what the combination buys
  • Name who the device is for; the cost claim is only strong relative to what they can currently afford

Archive entries are summaries compiled for study. Read them for how a project was structured, argued, and defended — not as a template to reproduce. Copying someone else's project is the one thing that will end yours.

Compiled by ResearchForge from the Society for Science public award announcement linked on this record. Names, hometowns, project titles and reported results are as published. The "why it worked" and "what to take from this" notes are ResearchForge's editorial reading of that public record — they are not statements by the students and not the judges' rationale. All rights to the original projects remain with their authors; no project materials are rehosted here.