Researchers at MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL), in collaboration with the Hasso Plattner Institute, have developed SustainaPrint, a toolkit that makes 3D printing both stronger and more sustainable. The system combines eco-friendly filaments with strategic reinforcement, reducing plastic use while maintaining durability.

The Sustainability Challenge in 3D Printing

Since its invention in 1983, 3D printing has become an essential tool for designers across disciplines, from architectural models to consumer products. However, the process still largely relies on petroleum-based plastics. While biodegradable or recycled filaments exist, they are often weaker and brittle under stress—limiting their application in structural or load-bearing designs.

This trade-off between strength and sustainability has been a key barrier to wider adoption of greener filaments. SustainaPrint aims to bridge that gap.

How SustainaPrint Works

Instead of printing an entire object with strong plastic, SustainaPrint uses finite element analysis to predict where a design will experience stress. Only those zones are reinforced with high-performance filament, while the rest is printed with more sustainable material.

For example, in tests using Polymaker’s PolyTerra PLA (biobased and eco-friendly) and stronger PLA from Ultimaker, researchers found that reinforcing just 20% of a part allowed hybrid prints to recover up to 70% of the strength of fully plastic versions. In some geometries, the hybrid prints even outperformed objects made entirely of strong PLA by distributing stress more evenly.

Applications for Designers

For architects and interior designers, SustainaPrint offers new opportunities to prototype lightweight models and components with reduced material impact. Product and packaging designers can explore functional items—such as hooks, headphone stands, or plant pots—that maintain durability without relying fully on petroleum-based plastics.

The toolkit also comes with a DIY testing device, enabling designers to evaluate the performance of recycled or locally sourced filaments before production. This opens possibilities for distributed manufacturing, where material stocks vary in quality and composition.

Towards Circular 3D Printing

SustainaPrint will be released as open-source software and hardware, making it freely accessible to designers, educators, and manufacturers. The team hopes it will not only reduce reliance on virgin plastic but also encourage the use of recycled and biobased alternatives.

As 3D printing becomes increasingly embedded in product development and design, innovations like SustainaPrint ensure that sustainability and strength can go hand in hand.

Source & image: MIT