Catan Injection Molding Workshop
By Aron Petau • 4 minutes read •
Playing with Recycled Plastic
On January 31st, 2026, we hosted an experimental workshop at Wertstatt Moabit, REFO's community makerspace focused on plastic recycling and sustainable manufacturing. The workshop brought together board game enthusiasts, sustainability advocates, and curious makers for a unique hands-on experience: creating custom Catan game pieces from recycled plastic using injection molding.
From Waste to Game Pieces
The workshop explored the practical dimensions of plastic recycling, taking participants through the entire process from sorted plastic waste to finished game components. We used injection molding machines to create three-dimensional hex tiles and meeples for the classic board game Catan, with each participant contributing to a complete playable set.
What We Made
- 3D Hex Tiles: Resource tiles with custom designs
- Meeples: Player pieces and settlements
- Custom Components: Individualized game pieces
Manufacturing Stations
The workshop was organized around three distinct production stations, each teaching different aspects of plastic manufacturing:
Plate Press Station: We used a heated plate press to create the flat hexagonal game tiles. Participants learned to measure precise amounts of shredded recycled plastic, load it into CNC-milled aluminum molds, and apply controlled heat and pressure to create smooth, colorful hex tiles. The plate press allowed for experimentation with different plastic mixtures, creating unique marbled patterns in each tile.
Injection Molding Station: The injection molding machine was the heart of the workshop, used to create three-dimensional game pieces like meeples and resource tokens. Participants learned to operate the machine safely, control temperature and injection pressure, and time the cooling process. This station demonstrated industrial-scale manufacturing techniques adapted for small-batch production.
Post-Processing Station: After molding, pieces needed finishing work. At this station, participants learned demolding techniques, removed excess material (flash), sanded rough edges, and quality-checked their pieces. This hands-on finishing work gave everyone an appreciation for the complete production cycle and ensured all game components were smooth and playable.
Hands-On Manufacturing
Participants got direct experience with:
- Material Preparation: Sorting and preparing recycled plastic for processing
- Injection Molding: Operating professional injection molding machines
- Design Iteration: Creating and testing custom molds
- Quality Control: Finishing and refining game pieces
The workshop demonstrated how injection molding can transform recycled materials into functional, durable objects while teaching practical skills in both manufacturing and sustainable design.
Community Impact
The complete Catan game we produced during the workshop was donated to a public institution, making it available for community use. Participants also created their own pieces to take home, ensuring everyone left with both knowledge and a tangible reminder of what's possible with recycled materials.
Gallery
-
A full Catan set
-
Finished game
-
Hex tiles in CNC form
-
Making trees
-
Ore tiles
-
Shredded raw material
-
The first molded parts
-
The injection machine
-
The workbench
-
Trees with 3D pen
Workshop Details
- Location: Wertstatt Moabit (underground workshop), Wiclefstraße 31, 10551 Berlin
- Duration: 5 hours (13:00 - 18:00)
- Organizer: REFO Campus / Wertstatt Moabit
- Fee: 22 Euro
- Focus: Adult learners interested in prototyping, sustainability, and hands-on manufacturing
This workshop represented an intersection of several interests: game design, circular economy principles, community engagement, and practical manufacturing skills. By choosing a familiar game like Catan as our project, we made the technical aspects of injection molding and plastic recycling more accessible and immediately rewarding.