Ethan Clarke
3D printing is a popular method for creating physical objects from digital models. The raw material used in this process is called filament, which is typically made from thermoplastic materials such as PLA, ABS, and PETG. As 3D printing becomes more common, so too does plastic waste. To reduce this waste, it is possible to recycle plastic into filament for 3D printing. This can be done at home or with specialised machines, such as the GP20 Plastic Shredder, which can recycle a wide range of thermoplastics, including PLA, ABS, and PEEK. The recycled filament can then be used in 3D printing, reducing waste and promoting eco-friendly manufacturing.
| Characteristics | Values |
|---|---|
| Plastic type | PET, rPET, PLA, ABS, PETG |
| Plastic source | Plastic bottles, old household appliances, failed 3D prints |
| Filament diameter | 1.5 mm, 1.75 mm, 2.85 mm |
| Filament temperature | 180-220°C for PLA, 220-250°C for ABS, 260-270°C for PETG |
| Bed temperature | 70°C for PETG |
| Print speed | 20 mm/s |
| Process | Clean, shred, melt, extrude, dry, post-process |
| Tools | Plastic shredder, filament maker, 3D printer, cutter blade, slicer software |
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What You'll Learn
Identify plastic type
Identifying the type of plastic is essential when making 3D printer filament from recycled plastic. The type of plastic determines its suitability for recycling into filament and the optimal processing temperature.
One way to identify the plastic type is by checking the distinctive number inside the standard “recycle” symbol on almost all plastic products. This symbol typically consists of a code inside a triangle, known as the Resin Identification Code (RIC). The RIC helps determine whether the material can be recycled into filament and is recognised by recycling centres.
Another method to identify the plastic type is through a burn test. This involves heating a metal or glass stirring rod until it glows red or orange (approximately 500°F / 260°C) and pressing it against the plastic sample. If the sample softens, it is a thermoplastic; if it doesn't, it's likely a thermoset. Subsequently, hold the sample to a flame and observe its behaviour, such as the colour of the flame, nature of smoke, presence of soot, and whether the sample drips. Different plastics have distinct burning characteristics, enabling identification.
Additionally, some plastics can be identified by their unique smell when melted. For example, ABS and PLA have distinct melting points and smells, allowing differentiation. However, it is crucial to avoid inhaling toxic fumes during this process.
Identifying the type of plastic is crucial for successful recycling and 3D printing. Different plastics have varying melting temperatures and characteristics, impacting the recycling process and the final product's quality. For instance, PLA typically extrudes at 180-220°C, while ABS extrudes at higher temperatures of 220-250°C. Sorting plastics by type before shredding and extruding ensures optimal processing and prevents material degradation.
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Shred plastic
Shredding plastic is an important step in the process of recycling plastic for 3D printing filament. It is the step that comes before feeding the shredded plastic into a filament-making machine.
There are several plastic shredders on the market designed for this purpose, including the 3devo GP20, the Felfil Shredder, and the Polystruder GR PRO. These machines vary in size, with the Felfil Shredder claiming to be the most compact option, and the 3devo GP20 being described as compact enough to fit on a desk. The Polystruder GR PRO is a more heavy-duty option, with a unique double-sided cutting blade design that gives it a longer blade life than other shredders. It also features an in-built algorithm called ShredAI, which allows it to detect the material hardness and adjust its speed and power accordingly.
When choosing a plastic shredder, it is important to consider the types of plastic you will be working with, as different plastics have different melting temperatures and characteristics. For example, PLA typically extrudes at temperatures between 180-220°C, while ABS extrudes at higher temperatures, usually between 220-250°C. Therefore, it is important to sort plastics by type before shredding them, to ensure they are melted at the correct temperature and to prevent material degradation.
It is also worth noting that not all plastics are suitable for filament recycling. Plastics with a clear recycling symbol are generally better candidates. Additionally, it is advisable to process similar types of plastics together, as mixing different plastics may affect the final filament quality.
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Melt plastic
The process of recycling plastic into 3D printer filament involves several steps, and melting plastic is a crucial stage in this process. Here is a detailed description of how to melt plastic to create 3D printer filament from recycled plastic.
Firstly, it is essential to understand the different types of plastic and their unique characteristics. The most common type of plastic used in 3D printing is thermoplastic, including PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), and PETG (Polyethylene Terephthalate Glycol). These plastics have different melting temperatures and properties. For instance, PLA typically melts at temperatures between 180-220°C, while ABS requires higher temperatures of 220-250°C. Sorting the plastics by type before melting is crucial to prevent material degradation.
Next, the chosen plastic must be shredded into small pieces or granules. This can be done using a plastic shredder, such as the GP20 Plastic Shredder, which is designed to efficiently shred a wide range of thermoplastics, including PLA, ABS, and tougher polymers. This step ensures that the plastic is in a suitable form for melting and extrusion.
The shredded plastic granules are then fed into a filament maker, such as the Filament Maker ONE or Filament Maker TWO. These machines allow for precision control over temperature, extrusion speed, and filament quality. The temperature settings are particularly important as they directly impact the melting process. The optimal temperature range depends on the type of plastic being used. For example, commercial PLA filament typically melts between 190-220°C, but recycled PLA may vary due to impurities or changes in material properties. It is recommended to start with a temperature in the middle of the range and adjust in small increments until the optimal melting point is achieved.
During the melting process, the plastic granules are heated and extruded through a nozzle, forming a continuous filament. This filament is then cooled and collected on a spool, ready for use in a 3D printer. The diameter of the filament is crucial, typically measuring between 1.75 mm and 2.85 mm for most 3D printers.
It is important to note that melting plastic into filament requires specialized equipment, and the process can be expensive and time-consuming. Additionally, the quality of the recycled filament may not match that of commercial filament, and it may be more suitable for test prints or less detailed projects. Nevertheless, with the right tools and techniques, it is possible to successfully melt recycled plastic and create usable 3D printer filament.
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Extrude filament
Extruding filament is a crucial step in the process of recycling plastic into 3D printer filament. It involves melting sorted plastic pieces and shaping them into a filament with the desired diameter. Here is a detailed guide on how to extrude filament:
Sorting and Shredding:
Firstly, it is essential to sort the plastic waste by type, separating materials like PLA, ABS, and PEEK. This sorting ensures that the plastic is melted at the correct temperature to prevent material degradation. After sorting, the plastic is shredded into small pieces or granules, which can be done using a plastic shredder like the GP20.
Melting and Extrusion:
The shredded plastic is then fed into an extruder, such as the Filament Maker ONE or TWO by 3devo. This machine melts the plastic at the appropriate temperature, typically between 180-250°C depending on the plastic type, and extrudes it through a nozzle. The extruder allows control over temperature, extrusion speed, and filament quality, ensuring a consistent filament.
Diameter Control:
Achieving the correct filament diameter is crucial for successful 3D printing. Most 3D printers use filament with a diameter of 1.75 mm or 2.85 mm. However, homemade extruders may produce filament that varies in thickness. To address this, you can use a tool to cut and refine the filament, ensuring it meets the required diameter specifications.
Post-Processing:
After extrusion, the filament may require additional post-processing steps before it is ready for use in a 3D printer. This can include drying the filament to remove any moisture and ensuring it is free-flowing and ready for printing.
Extruding recycled filament offers an innovative way to transform plastic waste into valuable material for 3D printing, contributing to sustainability and reducing environmental impact.
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Adjust printer settings
Adjusting your printer settings is a crucial step in successfully using recycled plastic filament. Here are some detailed instructions and considerations to help you optimise your printing process:
Firstly, it is important to understand the characteristics of different thermoplastics. The most common thermoplastics used in 3D printing are PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), and PETG (Polyethylene Terephthalate Glycol). Each type of plastic has unique properties and responds differently to heat. For example, PLA is biodegradable and made from renewable resources, while ABS is stronger and more flexible but emits fumes when melted. Knowing these characteristics will guide your printer settings.
Temperature settings play a critical role in achieving successful prints. Different plastics have different melting temperatures, so sorting plastics by type before printing is essential. For instance, PLA typically extrudes at 180-220°C, while ABS extrudes at higher temperatures of 220-250°C. Setting the temperature too high can lead to uneven melting and poor print quality. Therefore, it is advisable to start with a middle-range temperature and adjust in small increments until the optimal temperature is found.
The diameter of the filament is another crucial factor. Most 3D printers use filament with a standard diameter of 1.75 mm or 2.85 mm. Setting up a thinner filament diameter in the slicer can improve layer bonding and print quality.
When using recycled filament, it is important to consider potential impurities or changes in material properties that may affect the optimal printing temperature. Online resources can be leveraged to identify the appropriate settings for your chosen recycled filament.
Finally, bed temperature and print cooling settings can also impact the printing process. For example, when using PETG filament, a bed temperature of 90°C can improve adhesion. Turning off print cooling can enhance adhesion between layers, but it may be necessary to decrease the print speed to compensate.
By carefully adjusting these printer settings, you can optimise your printing process and create high-quality prints using recycled plastic filament.
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Frequently asked questions
The process involves shredding plastic waste into granulate, which is then fed into a filament-making machine to produce new filament. The filament is then heated and extruded through a nozzle onto a build plate, layer by layer, to create a 3D object.
Some common types of plastic that can be recycled into filament include PLA, PET, ABS, and PEEK. It's important to note that not all plastics are suitable for filament recycling, and different plastics have different melting temperatures and characteristics.
A plastic shredder is needed to shred the plastic waste into granulate. Then, a filament maker or extruder is used to create the filament. Some companies offer machines specifically designed for this process, such as the 3devo Filament Maker and the GP20 Plastic Shredder.
