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Summary
Designed an automated machine to convert thermoplastic parts from FDM 3D printing into recycled PLA, ABS, and PETG filament spools to enabling zero-waste manufacturing within a small desktop footprint smaller than any 3D printer.
Problem Statement
FDM 3D printing is an amazing tool for making prototypes or quick plastic parts. However, 3D printing accumulates a significant amount of plastic waste, yet proper disposal or recycling efforts have room for improvement.
Most of the common materials in FDM 3D printed can be fully recycled back into filament rolls; thus achieving zero-waste manufacturing. I specifically designed this machine to automate the full recycling process & accommodate to customers ranging from hobbyists to 3D printing farms.
Recycling Process & Modules
Thermoplastic parts/scrap made of PLA, ABS, or PETG can be heated & reshaped. By first understanding the recycling process, the project was then divided into modules each with inputs, outputs, and requirements.
Shredding Module
What: Granulates 3D printed parts into small particles of ~2mm diameter to achieve efficient heating of the thermoplastic. Design took inspiration from personal blenders, leveraging packaging & blade configuration.
By increasing the exposed surface area and reducing thickness of the plastic, prior to heating, the amount of heat energy required to heat particles to the glass transition temperature.
Heating Module
What: Achieves uniform heating of granulated plastic, extruding out a continuous length of 1.5mm circular profile rod to form a recycled filament spool. Design took inspiration from injection molding machines with a reciprocating screw and staged heating to achieve better consistency and uniformity in the extruded material.
Inspiration: Injection Molding Machine Heating Chamber
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