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.

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.

As the demand for recycled materials grows, Falconer plans to export his recycling solution to harbors around the world, providing a way for countries without established waste systems to turn their discarded fishing nets into a profitable raw material. With the European Union's target of 20% recycled plastic in automobiles by 2035, Falconer's innovative approach is poised to play a significant role in the transition to a more sustainable future.