Chloe Zhang
Plastic is a versatile material that can be used to create a variety of projects, from plastic models of military vehicles to recycling plastic for household use. Building with plastic requires knowledge of the different types of plastics and their unique characteristics, as well as the appropriate tools and techniques for assembly. In this guide, we will explore the steps to build with plastic, including choosing the right type of plastic, preparing and assembling components, and applying finishing touches to create a durable and aesthetically pleasing final product.
| Characteristics | Values |
|---|---|
| Plastic types | ABS, HDPE, Polypropylene, Polyethelene, TEO |
| Plastic creation | Extraction of raw materials, refining process, compounding, extrusion or moulding |
| Plastic uses | Building models, recycling, automotive design, enclosures, mounting solutions |
| Plastic tools | Sprue cutters, hobby knife, tweezers, sanding sticks, plastic cement, glue |
| Plastic adhesion | Epoxy resin, fiberglass cloth, epoxy putty, spray foam, alcohol |
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What You'll Learn
Gluing and welding plastic
Gluing plastic can be tricky, but knowing the type of plastic is key. Plastics in categories 1, 2, 4, and 5 are very difficult to glue. For these plastics, look for an adhesive for polyethylene or polypropylene. Category 3, PVC, is most commonly used in plumbing. For gluing PVC, there is a two-part primer and PVC solvent cement commonly available in most hardware or home improvement stores. Items in category 6 are made of polystyrene, and a poly cement, epoxy, or cyanoacrylate will form a sufficient bond. Category 7 is a catch-all for plastics that don’t fit into the other categories, including polycarbonate and acrylic. For polycarbonate, an epoxy will work best. Category 9 is for ABS plastics, and while ABS solvent adhesives are available, they do warp the plastic. For optimal results, an epoxy should be used. Cyanoacrylate glue may also work well for this application.
In some cases, a recycling logo and code may not be marked on the item, and you will have to guess or research the type of plastic. If the plastic is hard like a bucket or milk crate, it is likely to be polyethylene or polypropylene. Clear, brittle plastics like imitation glass or CD cases are usually polystyrene, and a poly cement will work best on these. Legos are made of ABS, so if the plastic feels similar, use an epoxy cement.
Some plastics simply will not take glue. This is due to the low surface energy of polymers, which means that they will be poorly wetted by any adhesives, reducing their effects. As a last resort, there is plastic welding where you melt the plastics back together.
Plastic welding is a process where you clean the plastic components and prepare them for the "Tacking" step. A Rotary Burr is used to provide a "V" groove along the weld line. Once the "V'ing" is complete, the "Tacking Nozzle" can be used to ensure close joint interfaces and alignment of broken parts. Unlike metal welding, "Tacking" is carried out wherever you intend to place the welding rod, not just at the ends of the welding area. After welding, attempt to remove the rod with a pair of pliers, pulling at 90 degrees to the welded part. If the rod snaps off, leaving the material on the parent, you know you have a match.
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Using epoxy putty
Epoxy putty is a versatile and durable material that can be used to fill cracks, holes, and irregularities in various surfaces. It is a 2-component filler consisting of an epoxy resin and hardener. When mixed together, they create a strong and flexible paste that adheres to various materials such as wood, concrete, metal, and plastic.
One example of epoxy putty is PlasticWeld, a hand-mixable, fast-setting epoxy putty that forms a durable bond with most major plastic types. It can be used to repair and rebuild various plastic compounds and surfaces, such as ABS, PVC, and CPVC pipes, auto bumpers, vinyl surfaces, and more. After kneading the two-part formula together by hand, PlasticWeld takes about 25 minutes to set and cures in 2-3 hours. It cures to an off-white colour and can be moulded, shaped, sanded, drilled, cut, and painted.
When using epoxy putty, it is important to follow the instructions on the product and ensure proper ventilation. The putty should be thoroughly kneaded with fingers until a uniform colour is achieved before applying it to the desired surface.
Epoxy putty can be used for a variety of applications, including repairing damaged surfaces, filling holes, and levelling imperfections. It can also be used for cosmetic purposes, such as filling cracks in concrete countertops, sinks, and garden statues to create a smooth, waterproof surface.
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Recycling plastic
Plastic recycling is the processing of plastic waste into other products. Recycling can help reduce dependence on landfills, conserve resources, and protect the environment from plastic pollution and greenhouse gas emissions. However, it is important to note that recycling rates for plastic lag behind those of other materials such as aluminium, glass, and paper.
The process of recycling plastic typically involves melting and reforming it into new items. This can cause polymer degradation, and the waste must be sorted by colour and polymer type, which can be complicated and expensive. One alternative is feedstock recycling, where waste plastic is converted into its starting chemicals before becoming fresh plastic. This method, however, incurs higher energy and capital costs.
Another challenge with plastic recycling is the economics involved. Creating new plastic is relatively cheap, whereas recycling can cost as much as or more than the material is worth. Despite years of recycling campaigns, less than 10% of plastic waste is recycled globally, and the amount of plastic waste dumped in the environment continues to increase.
To recycle plastic at home, one can melt down and reuse plastic items such as milk jugs and plastic bags. The plastic should be cut into small pieces and placed in a preheated oven at 350 degrees Fahrenheit. It is important to ensure proper ventilation as the melting plastic may release nasty fumes. Once melted, the plastic can be moulded and solidified, but it must be kept under pressure while cooling to prevent warping.
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Tools for building with plastic
When building with plastic, there are a variety of tools that can be used to achieve the desired results. The specific tools required will depend on the complexity and precision needed for the project. Here are some essential tools for building with plastic:
- Plastic Model Kits: These kits are specifically designed for building with plastic and typically include a range of tools and supplies. They are ideal for beginners and experienced builders, offering a selection of beginner-friendly and professional-level tools.
- Mr. Hobby Mr.Basic Tool Set: This toolset is tailored for plastic modelling and includes essential tools for building and customizing plastic models.
- Gundam Model Kit Tools: Gundam offers a wide range of tools for building plastic models, catering to both beginners and experienced builders. Their selection includes primer tools, resin/conversion kits, and painting supplies.
- Dremel Rotary Tool: A Dremel rotary tool is a versatile power tool that can be used for a variety of tasks when working with plastic. It can be equipped with different attachments for cutting, grinding, sanding, and drilling.
- Respiratory Protection: When working with plastics, it is important to prioritize safety. Respirators or respirator cartridges can protect against potentially harmful gases and vapours that may be released during certain plastic-working processes.
It is important to assess the specific requirements of your plastic-building project and select the appropriate tools accordingly. Additionally, ensuring that you have a dedicated workspace with adequate ventilation and safety precautions in place is crucial for a successful and safe building experience.
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Choosing the right plastic
Industry and Application
The right plastic will make manufacturing easier and improve the longevity and durability of your end product. For example, any moving part used in automation needs to be made to remain smooth over years of use. A single flaw in a mechanical component can lead to sticking parts and machine breakdown. Plastics are recommended over metal since plastics have higher friction resistance. Similarly, electronics need to stay clean, dust-free, safe to handle, and reduce the risk of accidental electrocution. Acrylonitrile Butadiene Styrene (ABS) plastic is ideal for electronic components due to its good stability and insulating properties.
Environmental Impact
The environmental impact of plastics should also be considered when selecting a plastic. It is important to choose plastics that are recyclable or biodegradable and have a lower carbon footprint than traditional plastics. Using recycled plastic is an effective way to reduce costs while also being environmentally friendly.
Temperature
Each individual plastic has its own unique temperature tolerances, which makes the specific needs of your application an integral part of the selection process. The operating temperature range measures the maximum (and sometimes minimum) temperature a material can endure before desired qualities begin to drop off.
Stress, Weight, and Pressure
Structural materials need to be able to endure immense amounts of stress, weight, and pressure over a sustained period. The right material can provide months, years, or even decades of reliability while under constant pressure. Understanding the kind of stress, weight, and pressure the structure may encounter will help ensure the material selected promotes structural integrity.
Local Weather Conditions
If you are building outdoor structures, it is crucial to use custom, high-quality plastic materials. Make sure to consider local weather conditions and choose a type of plastic that can withstand them. Polycarbonate plastic is an excellent material for outdoor use as it provides all-weather protection. TPO's inherent resistance to harsh weather conditions, including UV radiation, makes it ideal for products exposed to sunlight and temperature fluctuations.
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Frequently asked questions
Essential tools include sprue cutters, a hobby knife, tweezers, sanding sticks, and plastic cement.
This depends on the project. ABS plastic is strong and suitable for gluing or welding, while HDPE plastic is good for low-stress applications.
Yes, you can melt down and reuse plastic found in your house, such as plastic containers or bags. Cut the plastic into small pieces, preheat your oven to 350 degrees Fahrenheit, and melt the plastic in a pan or mold.
You can join plastic parts together using glue or plastic cement. Apply the glue in controlled amounts to avoid using too much, and consider using supports like rubber bands or masking tape to hold larger elements in place while they dry.
To create a smooth finish, you can use a process called "sanding." Lightly sand the edges of the plastic with sanding sticks or coarse sandpaper to achieve the desired smoothness. You can then apply a final layer of polished varnish to protect and enhance the appearance of your build.
