Across Kenya, waste has become a formidable menace in the quest to develop urban planting and green spaces. For years, there have been calls from affected industries, including the government, for sustainable solutions to this growing problem. JKUAT researchers have risen to the occasion, embracing the challenge head-on. What once seemed like environmental burdens, plastic scraps, coconut husks, even agricultural by-products, are now becoming the building blocks of cutting-edge energy technologies.

Led by Dr. James Mutua and his team at JKUAT, the research project is using additive manufacturing (AM) to turn wastes into real-world energy solutions such as fuel cells, bioplastics, wind turbines, and more.

The study gives a glimpse into how additive manufacturing (AM) can be a game-changer in both environmental management and energy resilience. The researchers used nano-silica taken from agricultural waste to make strong 3D printing materials. These new materials are much better than most recycled plastics, with tensile strengths going beyond 6,500 MPa.

At the same time, the team is producing real-world devices and prototypes. A 10-stack PEM fuel cell, a bio-oil pyrolysis unit, and 3D-printed wind turbine blades have already rolled out from the lab not as concepts, but as functioning units.

Additionally, the equipment to make these innovations from plastic extruders to heat press machines has been designed, fabricated, and optimized locally. These low-cost, efficient tools make the process scalable for wider community use.

Environmental and social impact are woven into every layer. This has been incorporated to create practical pathways for cleaner cities, skilled jobs, and decentralized power generation. Every component is tested, every output measured, and every student trained is part of a bigger shift toward sustainable engineering.

With support from national and international partners, and a growing record of peer-reviewed publications and graduate-level training, the team has now set apart JKUAT as an Advanced Additive Manufacturing Hub .