16-year-old Massachusetts student built a machine that turns 3D-printer waste into reusable material, won $75,000 award

What if the plastic waste left behind by a 3D printer could be turned into new material instead of being thrown away? A 16-year-old student from Massachusetts decided to find an answer. Benjamin Davis developed a compact recycling system that converts discarded 3D-printing material and other plastics into reusable filament, and his idea earned him a $75,000 award at one of the world's biggest science competitions.

How did the teenager's recycling machine work?

Davis, a student at Bishop Feehan High School in Attleboro, Massachusetts, created the system as part of his science research project. His machine is designed to take plastic waste, including material left over from 3D printing, and turn it back into filament that can be used in another 3D-printing project.

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His project combined two different plastic-processing methods: pultrusion and extrusion. According to the Society for Science, bringing the two processes together made the system about 45% more efficient. The machine was also designed with ordinary users in mind. It can produce higher-quality recycled filament while being easier to operate than some existing home recycling systems. One of its biggest advantages is its cost. The Society for Science says Davis' design costs about 90% less than commercial recycling machines.

Why is 3D-printing waste a problem?

3D printers are increasingly used in schools, homes, laboratories and businesses. But the printing process can generate a surprising amount of discarded plastic. According to the Society for Science, up to 67% of the filament used in a typical 3D-printing project may end up as waste. Davis' machine is aimed at putting some of that material back into use instead of sending it to the bin. The idea also fits into a larger push towards more sustainable manufacturing, where materials are reused rather than constantly replaced with new ones.

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He spent hundreds of hours improving the idea

The invention was not produced in a single attempt. According to the Massachusetts Science + Engineering Fair, Davis said he worked on the project for more than 800 hours and went through more than 50 component iterations and several redesigns. Speaking about his award experience, Davis said it was “one of the best weeks of my life” and that he was grateful for the opportunity to participate in the competition. His project eventually reached the 2025 Regeneron International Science and Engineering Fair (ISEF) in Columbus, Ohio.

How did he win $75,000?

Davis received a $75,000 Regeneron Young Scientist Award, finishing second in the competition's top award category. He was one of the young researchers recognised at the 75th annual ISEF, which brought together students from around the world. Science News also reported on Davis' achievement, describing his project as a desktop recycling system capable of turning 3D-printer waste into fresh filament.

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What does Benjamin Davis want to do next?

The award has encouraged Davis to continue working in the field. In a later interview with the Society for Science, he said his research in plastic recycling and extrusion had strengthened his plans to study advanced manufacturing and mechanical or materials engineering in college. His project may have started with plastic scraps from 3D printing, but the larger idea is simple: waste does not always have to be the end of a material's useful life. For Davis, the challenge was to build a machine that could give discarded plastic another chance — and make that process affordable enough for ordinary users.