# 230. 3D Printing Gets the Hannah Montana Treatment

- Show: [The Next Byte Podcast](https://hardwarepodcasts.com/podcast/the-next-byte-podcast)
- Published: 2025-10-07
- Length: 15m
- Page: https://hardwarepodcasts.com/podcast/the-next-byte-podcast/2025-10-07-230-3d-printing-gets-the-hannah-montana-treatment
- Listen: https://the-next-byte-wevolver.simplecast.com/episodes/230-3d-printing-gets-the-hannah-montana-treatment-by75cpVy

## Summary

The hosts discuss 'SustainUp Print,' an open-source software tool from MIT that enables dual-extruder 3D printers to mix strong virgin oil-based plastics with weaker, eco-friendly recycled or biodegradable filaments. By using finite element analysis (FEA) to identify critical stress zones, the tool reinforces only those areas with strong plastic while filling the rest with sustainable material, achieving 70% of full strength with only 20% virgin plastic. The conversation also touches on the limitations of recycled polymers due to chain degradation and the potential for this hybrid approach to optimize for cost and mechanical performance beyond just sustainability.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/the-next-byte-podcast/2025-10-07-230-3d-printing-gets-the-hannah-montana-treatment#t=0) Introduction and Sponsor Read
- [2:09](https://hardwarepodcasts.com/podcast/the-next-byte-podcast/2025-10-07-230-3d-printing-gets-the-hannah-montana-treatment#t=129) The Problem with Recycled Plastics
- [5:40](https://hardwarepodcasts.com/podcast/the-next-byte-podcast/2025-10-07-230-3d-printing-gets-the-hannah-montana-treatment#t=340) How SustainUp Print Works
- [10:32](https://hardwarepodcasts.com/podcast/the-next-byte-podcast/2025-10-07-230-3d-printing-gets-the-hannah-montana-treatment#t=632) Critical Analysis and Limitations
- [13:32](https://hardwarepodcasts.com/podcast/the-next-byte-podcast/2025-10-07-230-3d-printing-gets-the-hannah-montana-treatment#t=812) Future Potential and Conclusion

## Topics

- [Prototyping & iteration](https://hardwarepodcasts.com/topic/prototyping)
- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [EDA & CAD tools](https://hardwarepodcasts.com/topic/eda-and-cad-tools)
- [Sustainability & circular products](https://hardwarepodcasts.com/topic/sustainability-and-circularity)

## Most relevant to

makers and hobbyists

## Mentioned

- MIT (company)
- SustainUp Print (product)
- Mouser Electronics (company)

## Related episodes from other shows

- [Ep040: 3D Printed Everything, Strength v Toughness, Blades of Fiber, and What Can't Coffee Do?](https://hardwarepodcasts.com/podcast/hackaday-podcast/2019-10-18-ep040-3d-printed-everything-strength-v-toughness-blades-of-fiber-and-what-cant-c) (Hackaday Podcast)
- [483: There Are Two Wolves Inside Me…](https://hardwarepodcasts.com/podcast/making-it/2025-05-16-483-there-are-two-wolves-inside-me) (Making It)
- [Ep005: Undead Lightbulbs, Home Chemistry, and the Strength of 3D Printing](https://hardwarepodcasts.com/podcast/hackaday-podcast/2019-02-08-ep005-undead-lightbulbs-home-chemistry-and-the-strength-of-3d-printing) (Hackaday Podcast)
- [Ep 334: Radioactive Shrimp Clocks, Funky Filaments, Owning the Hardware](https://hardwarepodcasts.com/podcast/hackaday-podcast/2025-08-22-ep-334-radioactive-shrimp-clocks-funky-filaments-owning-the-hardware) (Hackaday Podcast)
- [Ep 348: 50 Grams of PLA Hold a Ton, Phreaknic Badge is Off The Shelf, and Hackers Need Repair Manuals](https://hardwarepodcasts.com/podcast/hackaday-podcast/2025-12-05-ep-348-50-grams-of-pla-hold-a-ton-phreaknic-badge-is-off-the-shelf-and-hackers-n) (Hackaday Podcast)

## Citing this page

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