Description
Build a plastic recycling machine to make 3D printable filament for the Ultimaker and other people's printers.
First (optional) step of the process is to melt plastic parts (such as bottle caps, failed prints, packages) into plastic pellets. This can be done by putting parts inside a heating recipient having a hole at the bottom. An irregular thread of material will come out and be sliced into small pellets.
Next step is to transform pellets or plastic parts (if they are small enough) into 3D-printable filament. This is performed by the extruder. An extruder is constructed from essentially two parts: a feeding mechanism, and a heater - chopped plastic parts or pellets are fed from a container into the feeding mechanism, which then pushes the plastic slowly through the heater to create the filament.
Goal
- Recycle failed/old prints and extruded plastic
- Recycle other plastics, such as PET bottles (caps), etc
- Experiment with new colors and materials
Obstacles
- Get a filament of repeatable thickness
- More complex = more difficult
- Ventilation preferable for ABS
Parts
| Part Name | Description | Progress | 3d model/images |
|---|---|---|---|
| Main frame | Main part holding all the parts together. | Done | TODO |
| Coupler | Holds the motor rotor and the screw together | Needs update with new motor rotor diameter (8mm) | TODO |
| Motor holder | Holds the motor (duh.) | Needs update with 3 holes mounting instead of 4. Thickness needs to be checked for usage with new motor | TODO |
| Screw holder | Aligns the screw with the tube. | May need more grease to reduce friction | TODO |
| Tube | Brings the plastic pellets/parts into a heated nozzle. Makes plastic filament (theoretically). Also the nozzle is exchangable with other nozzle models to allow various diameters of filament to be made | TODO |
Resources
Extruders
I'm guessing we should build something in between - not too simple but not too expensive either.
Misc
Progression
- 2013/11/22 - Starting experiments :).
- 2013/11/27 - Measure the temperature we can have with the current setup. Are there other ways to use the nichrome wire (on the extrusion head/on the tube/both) ? Also start experiments for the part that will transform HDPE into pellets (shattering vs melting i.e.). What's the best way to have both parts (recycling and filament making) in the same machine ? Also: plans, plans, plans - use a paper shredder to break used and new plastic into small bits.
- 2014/01/17 - Added a metal top on the end with a 3mm brass extrusion nozzle soldered to it. Next step is adding motorization and automation (i.e. temperature regulation)
- 2014/01/30 - A more polished version of the metal parts will be made by User:noskill's school polymecanics. The heated part and the nozzle will be removable.
- 2014/03/10 - Received the stepper motor and the arduino motor shield. Now the mechanics will make a first prototype of the machine in a few days. Also tested the temperature sensor under "real" conditions (~200°c) and worked perfectly.
- 2014/04/01 - The prototype is done ! And it's not even an April fools joke !
- 2014/06/11 - The motor used is not powerful enough in the current setup. Next step is to try adding a screw trough the rotor to get more torque and eventually to buy a new motor (DC, stepper ?).