Innovative 3D Printing Filament Derived from Recycled Fishing Nets Gains Traction in Automotive Industry

In a significant advancement for sustainable manufacturing, Fishy Filaments, a Cornish start-up, has developed a proprietary process to recycle discarded fishing nets into engineering-grade nylon suitable for 3D printing. This initiative addresses the dual challenges of plastic pollution and the demand for high-quality 3D printing materials.

Annually, over one million tonnes of fishing equipment are either discarded or lost in the world's oceans, posing threats to marine life and ecosystems. Traditionally, many of these nets, primarily composed of non-recycled nylon, are incinerated or sent to landfills, contributing to environmental degradation. The production of virgin nylon generates approximately two million tonnes of CO₂ equivalent emissions each year.

Founded in 2016 by Ian Falconer, Fishy Filaments has engineered a chemical-free process that deep-cleans and recycles smaller commercial fishing nets into high-quality nylon. This recycled nylon has garnered attention from major automotive manufacturers, including Ford and Mercedes-Benz, for potential use in 3D-printed car components. The company's method is environmentally efficient, with its only byproducts being dirty water and a minimal 3% of input net material.

The process begins with the collection of end-of-life nets from the Cornish hake fleet. These nets are then subjected to a proprietary cleaning and shredding procedure, transforming them into pellets suitable for 3D printing applications. The resulting recycled nylon has been tested and found to meet the stringent quality standards required for engineering applications, making it a viable alternative to virgin materials.

The automotive industry's interest in this recycled filament aligns with a broader commitment to reducing carbon footprints and embracing sustainable materials. By incorporating recycled nylon into 3D-printed car parts, manufacturers can decrease reliance on virgin plastics and lower greenhouse gas emissions associated with traditional manufacturing processes.

Despite its innovative approach and environmental benefits, Fishy Filaments has faced challenges in scaling its operations. The company has primarily relied on crowdfunding, grants, and research tax credits to fund its growth. Recently, it raised over £114,000 to build a commercial plant with a capacity of 20 tonnes per year. This facility aims to increase production efficiency and meet the growing demand from various industries seeking sustainable material solutions.

Looking ahead, Fishy Filaments plans to expand its impact by selling automated recycling plants globally. By doing so, the company aims to significantly reduce the number of fishing nets discarded in landfills or oceans, contributing to a more sustainable future. This strategy not only addresses environmental concerns but also provides a scalable solution for producing high-quality 3D printing materials from recycled sources.

The success of Fishy Filaments underscores the potential for innovative recycling processes to transform waste materials into valuable resources. As industries continue to seek sustainable alternatives, such advancements play a crucial role in promoting environmental stewardship and resource efficiency.