From cup to 3D printer: when waste becomes innovation
Planeta COPPE / Metallurgical and Materials Engineering / News
Date: 10/09/2026
Coffee grounds and 3D printing waste are given a new purpose as raw materials for a bioproduct developed at Coppe/UFRJ. Researchers at the Biopolymers and Bioengineering Laboratory (Biopoli) have developed new filaments for 3D printing by combining coffee grounds with waste polylactic acid (PLA) filaments—a biodegradable plastic produced from renewable sources.
The initiative combines waste reuse, a reduction in the use of virgin raw materials, and the development of new materials, in line with the principles of the circular economy. Instead of being discarded, these two types of waste are now integrated into a new production chain and give rise to a biocomposite with higher added value.
This development is part of the project “From Cup to Innovation: Coffee Grounds and 3D Printing Waste in Biocomposites,” led by Professor Rossana Thiré, coordinator of Biopoli within the Metallurgical and Materials Engineering Program (PEMM) at Coppe. The research aims not only to find a new use for these waste materials but also to develop an alternative with a lower environmental impact for filament production.
From coffee to 3D printing
Coffee grounds are incorporated into recycled PLA, a material widely used in 3D printing. Although PLA has an environmental advantage over conventional plastics because it is produced from renewable sources, its disposal remains a challenge, especially given the growing use of 3D printers and, consequently, the increase in waste generation.
“These are materials that would normally be discarded and that can now be used to create biocomposites, entering a new production chain. As a result, we’re able to make better use of this waste and minimize the generation of solid waste,” explains Rossana.
Environmental concerns are also a priority in the manufacturing of the new filament itself. The team developed a production process that does not use toxic solvents and allows for the reuse of water used in the process, reducing the environmental impact of production.
An idea that was born in a coffee shop
The research also stemmed from a conversation about a specific problem. Thomas Guerra, a senior mechanical engineering student at the UFRJ Polytechnic School, learned about the amount of coffee grounds produced daily by Café del Rio, a coffee shop located in the UFRJ Technology Park.
In a conversation with Marcos Brandão, co-owner of the coffee shop, Thomas learned of the need to find a way to repurpose the waste. From there, the idea arose to incorporate it into the project developed by Biopoli. Café del Rio became a partner in the research and began supplying the grounds used in the studies.
The project is being carried out by a multidisciplinary team that brings together researchers and students, including Thomas and Ph.D. candidate Gabriella Chagas from PEMM. The initiative received a grant from the UFRJ Technology Park’s Special Projects Program, with funding of R$90,000.
A material with new possibilities
The initial results already point to characteristics that could broaden the potential applications of the new material. According to Gabriella Chagas, the filament developed is more ductile than some commercial PLA filaments—that is, it can withstand greater deformation before breaking.
The next challenge is to scale up production and bring the material closer to the market. To this end, the team is seeking new funding, and also to expand the collection of waste that serves as raw material for the development.
Innovation that begins with a real problem
For Rossana, the project leaves a legacy that goes beyond the new material and the technology developed. The experience also helps foster a more practical perspective on innovation among the students.
The goal is for them to learn to identify real-world problems and think about how scientific knowledge can be transformed into solutions with practical applications.
