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Upcycling for the Battlefield: Off-Grid Containerized 3D Printing System Converts US Air Force Plastic Waste into On-Demand Combat Capabilities

September 26, 2025 Applications 126

US Air Force Employs Recyclable Materials to 3D Print Drone Components

The U.S. Air Force, in collaboration with innovative manufacturer re:3D, has successfully tested a containerized 3D printing and recycling system. This system can operate off-grid, directly converting plastic waste on base into usable tools and components.

The demonstration, led by the Air Force Rapid Sustainment Office (RSO) with technical support from re:3D, focused on validating the feasibility of recycling plastic to manufacture large, functional parts on-site, without relying on traditional power sources or external supply chains. This project falls under Phase II of the U.S. Department of Defense's Small Business Innovation Research (SBIR) program, aiming to explore the potential of using plastic waste on military bases as raw material for 3D printing.

U.S. Air Force Sergeant Ryan Plumbo said, "We were able to modify the printed fuselage and get it to fly. The second time, we were able to actually control it inside a racquetball court. It was a huge success."

Base personnel, after training, feed plastic scraps into the large-format Gigabot X 3D printer, which is designed for recycled plastic and can be operated through its container door.

From Trash to 3D-Printed Drones
The waste plastic 3D printing system is housed within two shipping containers, capable of processing waste and printing directly on location. The containers were transported to Cannon Air Force Base, where Airmen received training on operating the equipment.

A large-format print job in progress on the Gigabot X system.

The test system consists of two shipping containers integrated with large-format Gigabot X printers, plastic shredders, and drying equipment. The containers can be powered by generators or wind turbines, enabling completely off-grid operation. A team of Airmen, with support from both re:3D and the RSO's Advanced Manufacturing Program Office (AMPO), was trained on system operation, covering plastic recycling, processing, and the 3D printing workflow.

Placing waste plastic into a shredder for recycling.

Through trial and error, the team successfully printed a functional drone frame made entirely from recycled materials, such as PLA. Initially, the drone was too heavy to control effectively, but in a later iteration, it flew all the way to the ceiling of the base gym. The final version achieved stable, controlled flight, demonstrating the potential of recycled materials for functional applications.

An Airman holds up a successfully printed drone frame made from recycled materials.

Turning Recyclable Plastic from Waste to Asset
Beyond drones, the team also printed tools on-site, including cable ties for aircraft maintenance, drum wrenches, and wheel chocks. One of the recycled plastic wrenches was tested in the base's hydraulic shop, verifying the durability and practicality of the recycled parts. Additionally, the project tested interlocking structural components developed by the Air Force Academy for terrain reinforcement and erosion control. Although only a small section was printed for this demonstration, these components sufficed to show how 3D printing could support environmental applications like erosion control in the field.

Multiple batches of 3D-printed drone frames made from recycled plastic waste were printed and prepared for evaluation to test the material's properties.

A key aspect of the project was the ability to print without connection to a fixed power source. The shipping containers can operate on battery power, which can be charged by generators or wind turbines. As wind was not always as consistent as desired, the team primarily used generators, which operated without any issues.

The containers housing the mobile 3D printing setup, stationed at Cannon Air Force Base.

3D co-founder Samantha Snabes stated, "We've proven the technology works. You can set up these containerized 3D printing systems anywhere, and they enable large-format printing using waste streams. Our goal was to demonstrate its viability and continue the conversation with other groups that could benefit from a setup like this."

Currently, this project is an early example of the U.S. military using its own waste to create new products. Beyond military use, the partners are exploring applications for the 3D printing technology in scenarios like field operations or disaster relief, aiming to enable the on-site manufacturing of essential tools from plastic waste, even in areas lacking conventional power and material supplies.