Feilding Creators Giving 3D Printer Waste a Second Life
From their Fergusson Street studio in Feilding, the team at Black Rook Creations are giving 3D printing waste a second life, transforming leftover materials into unique, handcrafted items with purpose. Supported by Manawatū District Council’s Waste Not Want Not Fund, their mahi is a creative example of the circular economy in action.
Owned by Matthew Hurley, and supported by his partner Amanda Illston, Black Rook Creations specialises in creative, custom-made handmade and 3D printed products.
Through their daily mahi, Matthew became increasingly aware of the waste created through 3D printing. Although this waste is lightweight, it can be high in volume and is often destined for landfill. Rather than accepting this as an unavoidable part of the process, Black Rook Creations looked for a way to give the material a second life.
The business now keeps its own 3D printing waste and collects material from other businesses across the Manawatū to be repurposed. The PLA material (a thermoplastic polyester) is sorted, shredded and separated into colour categories before being heat-pressed into sheets to be laser cut into new products.
As a recipient of MDC’s Waste Not Want Not Fund, Black Rook Creations invested in specialised machines to complete this process in-house at their studio in Feilding. Within six months, the business had collected 91 kilograms of 3D printing waste (PLA material), diverting it from landfill while also helping reduce disposal costs for themselves and other businesses. Using the repurposed material, Black Rook Creations creates a variety of items, including personalised buttons for a local Palmerston North charity that knits infant clothing. Matthew estimates that one sheet of the repurposed material can produce around 50 buttons, each one unique in shape and colour, much like the handmade clothing they are created for.
Black Rook Creations’ approach to recycling and repurposing reflects the heart of MDC’s Waste Not Want Not Fund, showing how local ideas can make a real difference in reducing waste and supporting a circular economy across the Manawatū District. For Matthew and Amanda, giving 3D printing waste a second life has not only helped the environment, but has also become a meaningful and practical part of how they do business.
Do you have an idea that could help reduce waste in the Manawatū District? The Waste Not Want Not Fund is currently open for applications until Tuesday 30 June 2026, supporting local initiatives that reduce waste and encourage a circular economy. To learn more about the fund and make an application, visit: Waste Not Want Not Fund | Manawatū District Council
Photo Descriptions: 3D printed waste collected from businesses throughout the Manawatū.
Photo description: A sample of the 3D printed materials after being shredded.
Photo description: A heatpressed sheet of the material being laser cut into buttons.
Photo description: The final product! The buttons are complete.