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Filament Recycling Project
#563 04/02/2020 9:57 AM
Joined: Jan 2020
Posts: 124
Likes: 1
Locutus
Master Engineer
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Locutus
Master Engineer
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Additive manufacturing is great, right?

[Linked Image]

Remember the difference between additive vs subtractive manufacturing?

Subtractive manufacturing is when we cut smaller pieces out of a larger piece.

For example, I want to build a 4 ft x 4 ft table.

Plywood is sold in 4' x 8' sheets, so I would have to cut it in half...subtracting out a 4' x 4' section to use in my project.

Additive Manufacturing creates something by adding material until the object is finished. Like how a 3D printer heats plastic filament, and extrudes it through a tiny glue-gun like opening. Creating an object one tiny layer at a time.

For example, an aircraft engine might be over 1,000 parts that are pieces together using subtractive manufacturing. This would mean 1,000 places for that engine to come apart. Scary thought, right?

That same engine can be created in...lets say 15 parts. The end result is a stronger part, less waste, and faster build time. Star Trek, right?

It's great, but it does generate waste in the form of rafts, supports, and failed prints.

[Linked Image]

We can take this waste plastic and shred it in a heavy duty paper shredder. This will create small, easily melted pellets that we can put in a hopper.

The hopper would feed a heating element which would raise the filament back to its liquid state, then be re-extruded through a 1.75mm nozzle.

The resulting filament can then be spooled for re-use. Here's a page that goes through the process.

Still here?

Good. Now we can purchase one of these pre-assembled and ready to go, but they are costly! Check out the ProtoCycler+ for $1,700!!

[Linked Image]

There are also DIY Kits and projects out there. Check out the Filastruder Kit for $310.
[Linked Image]

Okay, your job is this! Go out and research all of the different options for Filament Recycling for 3D printing. I prefer a mechanical, in-house, solution where we can create our own, but if you find a better way, please present it! For example, there are companies you can ship your waste filament, and trade it for spools they sell at a discounted price.

After your research, reply to this post with a list of your three best options. Please also list pros and cons of each of your choices, along with a rough cost of the completed project.

Last edited by matthews; 04/02/2020 10:05 AM. Reason: formatting

-- Matthews

"Kindness is the language which the deaf can hear and the blind can see." - Mark Twain

"Those who cannot remember the past are condemned to repeat it."
George Santayana
Re: Filament Recycling Project
matthews #564 04/02/2020 4:33 PM
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journeyman
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journeyman
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The Filabot Recycling Service
It currently costs us $5.80 to recycle one pound of failed prints back into filament
Fliastruder kit pros and cons
Tough; Common; Non-toxic
High melting point; Unpleasant fumes
protocycler
safe or the environment

Re: Filament Recycling Project
matthews #571 04/06/2020 10:26 AM
Joined: Feb 2020
Posts: 13
journeyman
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journeyman
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Posts: 13
It's a common non toxic with the unpleasant fumes which in my opinions not a real good way on recycling.

Re: Filament Recycling Project
matthews #576 04/09/2020 3:45 PM
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journeyman
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journeyman
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A recyclebot can melt the wasted filament for reuse.

A cheaper way is to melt it with fire, but the filament will not be usable afterward.

If you have money to spare then you can spend $5.00 on a filament service.

Re: Filament Recycling Project
matthews #577 04/10/2020 9:05 PM
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enthusiast
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enthusiast
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Iv'e been researching and found a great machine that not only can recycle your old filament and make it reusable, but you can even create your own filament. It's the Bundle Felfil Evo & Spooler. It's compact and it includes a fan. It includes a sensor for high precision, it's suitable for mnay materials, etc.

Pros
-Small and Compact
-Easy and fast
-Recycles old filaments
-Can create your own filaments from unique materials

Cons
-Expensive

The current cost is at $1,083, which is a bit expensive, but overall it is worth it.

Re: Filament Recycling Project
matthews #578 04/14/2020 9:58 AM
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engineer
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One of the problems with recycling is transportation.3D printing has disrupted transportation. With its ability to decentralize manufacturing, parts can be emailed and printed on location. While the U.S. has started recycling programs, the amount of plastic produced every year overshadows what gets recycled. In addition, energy is needed to collect and process materials, which can impede on overall benefit to recycling.

pros: produces flexible prints

cons:requires tinkering with the printer

Re: Filament Recycling Project
matthews #593 05/06/2020 12:27 PM
Joined: Feb 2020
Posts: 13
journeyman
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journeyman
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I researched several filament extruder.

1. All3DP is the best option. You can build your own filament extruder for less than $100 and it can save about 90% of the cost of new filament. The link to the site is: https://all3dp.com/2/6-best-filament-extruders-to-build-or-buy
Pros- not expensive, save a lot of money
Cons-have to build yourself

2. RePlay3D is also a good option they do recycling. You send them your trash filament and they give your points toward new recycled filament. One pound of trash filament will make 1 spool of usable filament. They also give 20% discounts to schools and STEM programs.
Pros-saves money on new filament, recycles used/trash filament
Cons-Not having your own filament extruder

3. ReDo Tech, ProtoCycler+ is a filament extruder that cost about $1,699.99 but it can reduce your cost by 80%.
Pros- reduce expenses by 80%, make custom color filament, and can blend different kinds of filament.
Cons-Cost

These options are the best that I see.....What do you think?

Re: Filament Recycling Project
matthews #618 05/21/2020 9:06 AM
Joined: Jan 2020
Posts: 124
Likes: 1
Locutus
Master Engineer
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Locutus
Master Engineer
Joined: Jan 2020
Posts: 124
Likes: 1
Good information everyone! Project Phoenix just acquired a Filastruder!

[Linked Image]

Here is an assembly video. Let me know if you're interested in helping with the build.


Last edited by matthews; 05/21/2020 9:08 AM.

-- Matthews

"Kindness is the language which the deaf can hear and the blind can see." - Mark Twain

"Those who cannot remember the past are condemned to repeat it."
George Santayana

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