EcoFusionAI is a next-generation recycling and 3D printing system that transforms discarded PET bottles directly into filament using AI-driven automation. By eliminating traditional grinding steps, it lowers energy consumption and costs, making it accessible for schools, makerspaces, and small businesses. Its cutting bar precisely slices bottles for direct heating and extrusion, while a robotic arm autonomously loads new material. Semi-transparent panels foster user engagement, and intelligent dashboards provide real-time progress and environmental insights. This streamlined process not only reduces plastic waste but also promotes hands-on sustainability education. Through advanced simulation, development costs were minimized, ensuring a polished, user-friendly product. As a result, EcoFusionAI stands out as a unique, practical solution in the sustainable manufacturing sector, bridging creativity, efficiency, and environmental responsibility.