This study explores an innovative approach to repurposing PET (Polyethylene Terephthalate) bottles into sustainable and cost-effective 3D printing filament. PET bottles, widely used for packaging beverages and other consumer goods, contribute significantly to plastic waste and environmental pollution. Addressing this issue, our research focuses on developing an efficient thermal recycling process to convert PET waste into high-quality filament suitable for additive manufacturing. The methodology includes assessing material characteristics, mechanical properties, and printability to ensure that the recycled filament meets industry standards. In addition to process optimization, the study evaluates the environmental impact of using recycled PET compared to conventional filament sources such as PLA and ABS. By analysing energy consumption, carbon footprint reduction, and waste management benefits, we demonstrate the viability of integrating recycled PET into mainstream 3D printing applications. This research contributes valuable insights into sustainable manufacturing by promoting circular economy principles and reducing reliance on virgin plastic materials. The findings of this study provide a practical solution for mitigating plastic waste while fostering innovation in the 3D printing industry. By transforming discarded PET bottles into functional 3D printing filament, this project supports global sustainability efforts, making environmentally responsible production both accessible and economically feasible. The first section of the article outlines the preparation of recycled bottle material and the mechanical setup using mostly 3D printed parts. Second section details the electronic system for temperature control, filament winding, and cooling/heating functions. In the third section, filament production process and machine operation process explained step by step. Finally, presents experimental results comparing the recycled filament’s properties with commercial al