What is Ian Falconer's innovative solution to the problem of discarded fishing nets?

Ian Falconer has developed a way to convert discarded fishing nets into filament for 3D printing, turning a waste product into a valuable raw material.

How has OrCA, Falconer's company, been able to scale its recycling efforts?

OrCA has raised over £1 million from investors in more than 40 countries, which has funded the development of patented machinery that can convert over 20 kilos of nylon fishing nets per hour.

How are the recycled nylon products from OrCA being used?

The recycled nylon filament is sold to 3D printing companies and used to replace virgin plastic in a variety of products, from sunglasses and light shades to industrial components. Falconer is particularly proud of the nylon mixed with waste carbon fiber, which is used to make parts for racing bikes and super-light sunglasses.

Home / Environment / Cornish Entrepreneur Turns Discarded Fishing Nets into Valuable 3D Printing Material

Cornish Entrepreneur Turns Discarded Fishing Nets into Valuable 3D Printing Material

16 Oct

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Summary

Ian Falconer converts discarded fishing nets into filament for 3D printing
His company OrCA has raised over £1 million from investors in 40+ countries
Recycling process has less than 3% of the carbon impact of producing new nylon

Cornish Entrepreneur Turns Discarded Fishing Nets into Valuable 3D Printing Material

In 2025, Ian Falconer, a 52-year-old environmental and mining geologist, has found an innovative solution to the problem of discarded fishing nets. Falconer, who lives in Cornwall, was troubled by the heaps of abandoned nets he saw at the Newlyn harbour near his home. Determined to find a better use for this waste, he came up with a plan to shred, clean, and melt the worn-out nets, converting the plastic into filament for 3D printing.

Falconer's company, OrCA (previously Fishy Filaments), which he launched in 2017, has since raised over £1 million from small investors in more than 40 countries. This investment has funded the development of patented machinery that can convert over 20 kilos of nylon fishing nets per hour. Falconer claims the recycling process has less than 3% of the carbon impact of producing new nylon.