PulpMaker

What it does

PulpMaker is a mechanical 3D printer that transforms waste paper into 3D educational and creative objects without using electricity. It provides a sustainable and engaging way to support STEM learning and creative play where energy resources are limited.

Your inspiration

The primary inspiration for this project was the major earthquake that struck Turkey on February 6, 2023, leaving thousands of people homeless. While researching the living conditions in the temporary camps established after the disaster, I interviewed aid workers and volunteers and discovered that one of the most significant deficiencies was the lack of creative and educational activities essential for children's education and psychosocial development. I learned that the most abundant waste material was paper/cardboard and while resources like electricity were limited. Guided by Design for Social Impact, these insights inspired PulpMaker.

How it works

PulpMaker works through a simple, hands-on process. The process starts with pulp preparation. Waste paper is mixed with water and a natural binder, like starch or rice glue, to create a smooth, mouldable pulp. This pulp is then loaded into a hopper. As the user turns the crank, an internal screw conveyor gently pushes the mixture forward while keeping it moist and consistent. The material is extruded through a nozzle onto a build plate. Depending on the mode selected, users can either operate in Revolve Mode: ideal for simple cylindrical shapes using one hand or Free Mode: which allows for more complex forms by manually guiding the print head along the X and Y axes. Once the object is complete, it’s left to dry and harden into a durable final form. The entire mechanism, including movement across X, Y and Z axes and the rotation of the bed, is powered by gears, timing belts and clutches.

Design process

My design process began with field research after the 2023 earthquake in Turkey, where I spoke with aid workers to understand the challenges in temporary camps: lack of electricity, abundant paper waste, and a need for engaging tools for children. I started by experimenting with hand-mixed pulp recipes, balancing printability and strength. Inspired by traditional clay 3D printers, I adapted the mechanism to be fully manual and energy independent. Early prototypes used a gear-based system but proved unreliable, so I switched to a simpler belt and pulley design for smoother operation. The biggest challenge was extrusion: pistons squeezed water out, clogging the system. After many iterations, I designed a custom screw conveyor that gently guided the pulp without separating it, enabling consistent flow. I built detailed CAD models and modified most parts myself, testing multiple prototypes to improve pulp flow, structural stability, and ease of use for children. The final functional prototype was completed after thorough trials and manufacturing refinements. Throughout, user experience was central, like using a transparent body so kids could see the magic inside. The project evolved to its current form in late 2024, as part of my MA thesis at UAL.

How it is different

PulpMaker reimagines what a learning tool can be by turning waste paper into creative 3D objects without a single watt of electricity. Unlike conventional printers that consume power and rely on plastics, it runs entirely on a hand crank and upcycled pulp, making it truly sustainable and ideal for low-resource or crisis settings. Rather than a one-off assembly kit, PulpMaker is a platform for open-ended STEM exploration, empowering children to invent any shape they imagine instead of following predetermined instructions. Its transparent body and manual controls demystify mechanical principles gears, belts and force transmission become tangible lessons in physics. By blending sustainability, education and hands-on invention, PulpMaker exemplifies #DesignForSocialImpact.

Future plans

My vision for PulpMaker is to get it into the hands of the children who need it most. The next steps involve partnering with humanitarian organizations to test the device in different locations, gathering feedback from both children and educators. I aim to refine the design to make it more compact, portable, and durable for field conditions. Future iterations will explore the use of locally available binders and recycled materials. Once fully optimized, my goal is to distribute PulpMaker through aid organizations to underserved regions, where it can serve as a tool for creativity, learning, and resilience.

Awards