New 3D print method reduces plastic use without losing strength

MIT researchers from CSAIL and the Hasso Plattner Institute have developed SustainaPrint, a hybrid 3D printing system that significantly reduces plastic waste without compromising structural strength. The method uses simulations to identify stress-prone zones in a 3D model and selectively reinforces these areas with high-performance plastics, while printing the rest of the object with biodegradable or recycled filament. This targeted reinforcement approach cuts down plastic use and maintains durability, addressing the common trade-off between eco-friendliness and strength in 3D printing materials. In tests using Polymaker’s eco-friendly PolyTerra PLA and Ultimaker’s stronger PLA, SustainaPrint required only 20% reinforcement to regain up to 70% of the strength of fully reinforced prints. In some cases, the hybrid prints matched or even outperformed fully strong prints, demonstrating that strategic material mixing can enhance performance depending on geometry and load conditions. The system includes an open-source software interface for uploading models and running stress simulations, along with