From the Airplane Cockpit to the 3D Printer and Back | Offenburg University of Applied Sciences

A collage of three images: the first shows the PMMA scraps as green powder in a glass; the second shows a spool of the recycled filament; and the third shows an intercom module from Becker Avionics, in which, among other things, the green lenses were made from the recycled filament — The PMMA scraps are first turned into recycled filaments, which are then used to manufacture, among other things, the lenses for the intercom module produced by Becker Avionics (clockwise from the top left). © Hochschule Offenburg (2), Becker Avionics (1)

As part of the "BWGreenLabs" ideas competition sponsored by the Baden-Württemberg Ministry of Science, Research, and the Arts of Baden-Württemberg, Prof. Dr. Dominik Giel and his team at Hochschule Offenburg originally intended “only” to investigate the feasibility of recycling PET bottles and packaging waste into 3D printing filament. This was intended to drastically reduce the use of new filament in laboratory operations. Now, the research activities have been successfully expanded to include the technically challenging plastic polymethyl methacrylate (PMMA)—commonly known as acrylic or Plexiglas. A key impetus for this came from the company Becker Avionics.

This supplier of aviation communication and navigation systems generates large quantities of PMMA scraps during the production of certain components. The company made this “waste” available as research material. Staff at Hochschule Offenburg succeeded in removing impurities from the PMMA scraps in the lab and transforming them into polymer filament. This high-quality recycled material was then used in a 3D printing process to manufacture optical components—such as lenses for Becker Avionics’ devices. This process benefits the environment in two ways: It actively prevents plastic waste and is significantly more efficient due to the direct production of components, as it saves enormous amounts of material and energy.

As a result, the state-funded “BWGreenLabs” initiative—which aims to reduce resource consumption in University labs and make them more climate-friendly—is already having a significant impact on local businesses. This synergy effect and the successful conversion of industrial waste into high-tech components demonstrate the culture of sustainable research in Baden-Württemberg.