Tongo’s WoeLab Has Produced Over 20 3D Printers Made From E-Waste

Seven years after Afate Gnikou, an inventor working in a Tongolese maker space created Africa’s first 3D printer from e-waste, the piqued interest in this innovative construction led to the development of more than 20 other 3D printers made from unwanted electronics dumped in the West African nation of Togo, according to a report from WeeTracker. The technological revolution is happening at WoeLab (originally spelled WɔɛLab) known to many as street-level FabLab. The innovative hub was created by architect Sénamé Koffi Agbodjinou as a safe haven for technological democracy and is the first free laboratory of social and technological innovation of Togo to divert the use of discarded electronic material by creating sustainable technology.

WoeLab’s signature 3D printer, called the W.Afate is named after Gnikou’s early invention while the W stands for WoeLab. The W.Afate is inspired by the Prusa Mendel after one of the models was put together at WoeLab thanks to a kit brought from France. Gnikou quickly found a way to manufacture a machine that was easily reproduced and was based entirely on reusing discarded materials, mainly central processing units (CPUs), printers, scanners, Arduino boards, and lead wires.

Physically located in the Togolese city of Lomé, WoeLab has access to incredible supplies of unwanted electronic material. Unfortunately, the city, like many others in Africa, have large informal e-waste dumping and processing sites. Togo imports an estimated 500,000 tonnes of e-waste a year, and with one of the largest ports in West Africa, it has great potential to become the continent’s e-waste leading country. This is why turning used electronics into low-cost 3D printers could offer a potential solution to this risky, unhealthy, and illegal tendency that pose a threat to the environment and its inhabitants. Electronics contain toxic substances such as lead, mercury, cadmium, arsenic, and flame retardants, for instance, an old cathode-ray tube (CRT) computer screen can contain up to three kilograms of lead.

Innovative minds like Gnikou and Agbodjinou could provide solutions to a harsh African reality, by providing the know-how to co-create 3D printers, and drawing the population closer to technology.

Sénamé Koffi Agbodjinou (Credit: WoeLab)

Using crowdfunding from Ulule, a community-backed incubator of positive impact projects around the world, WoeLab raised over 4,600 dollars to develop the Woebots1 W.Afate, the first artisanal 3D printer, openSource and outside the RepRap family tree. The money was used to constitute the first series of practical kits based on the rational conversion of waste to 3D printers for fab labs around the world and to finance extension workshops in Togo.

Providing solutions adapted to African conditions and realities is an initiative on its own. The young architect and anthropologist understands what it takes to supply a broad context, both ethically and productively, to bring the various social strata in the city closer to technology, by offering the ability to create their own machines thanks to very detailed and simplified documentation that explains how to manufacture the W.Afate in 10 steps. The company claims to ambitiously think about African cities around these places of innovation. Under the SiliconVilla program, WoeLab has helped create and incubate 11 collaborative startups working around waste management, and resources.

More than a year ago, on the weekend following the opening of the research and exhibition project Digital Imaginaries: Africas in Production, Agbodjinou described WoeLab as “a utopia where everyone can launch projects to have an impact in the neighborhood and address ways to collect waste.” 

Moreover, the founder of WoeLab, revealed that since 2013, they had launched a second lab called WoeLab Prime, an incubator for startups and a way to identify the great potential of young children by incorporating hackathons, coding classes, and more. Both WoeLab sites also have 600 square meters of space each that are used as living quarters for people to visit.

As the biggest tech hub in Western Africa, they are not only interested in continuing to manufacture their pioneering W.Afate, which has become very well known around the world, but they have also developed a new 3D printer that they expect to commercialize, the Woebots Tavio. Agbodjinou had described that, although W.Afate is an incredible concept that encompasses sustainability, creativity, and knowledge, it is very difficult to build industrially because it relies on electronic waste, and he said that it’s not easy to find the same e-waste for every machine. 

The W.Afate 3D printer (Credit: WoeLab)

Powered by L’Africained’Architecture – an activist structure also set up by Agbodjinou to promote an original approach to planning and design in Africa – the WoeLab has become a very popular site for young people of Lomé with a curious desire to learn. Creating 3D printers with material that would otherwise end up in dumps, or incinerated, helps these communities value the need for sustainability in their designs, and like most brilliant ideas, the WoeLab innovation space has encouraged the development of other makers pace, fab labs and creativity centers that manufacture disruptive technology, like students in Tanzania’s Buni Hub, who also build an e-waste 3D printer just three years after WoeLab was created.

While encouraging students to manufacture 3D printers, WoeLab also provides the community of Lomé an opportunity to generate a tool that can improve their lives, empowering everyone to become a growing force for change. Every year, we generate 50 million tons of electronic waste worldwide, and 85 percent of these products are discarded in landfills or incinerators. This should be a great incentive to follow in the footsteps of Agbodjinou, who early on saw what others didn’t, potential to create a 3D printer out of junk.

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Eco-Friendly 3D Printing Using an Ecostruder, Recycled E-Waste and Solar Power

Electronic devices are a part of daily life for people across the world – laptops, smart phones, tablets, fitness bands, etc. They’re wonderful to have for many reasons, but none of these devices last forever, and when they’re discarded, they can do serious harm to the environment. Recycling programs are springing up that can refurbish and reuse some of the electronics in the devices, but what about all the plastic that left over? In a paper entitled “The Recycling of E-Waste ABS plastics by melt extrusion and 3D printing using solar powered devices as a transformative tool for humanitarian aid,” a group of researchers discusses how they took ABS plastics found in electronic waste and recycled them using 3D printing.

The researchers used waste plastics from discarded electronic devices within Deakin University‘s School of Engineering. These plastics included the outer casing from devices such as old computers, laptop docking stations and desktop telephones. They cleaned the plastic if needed and then broke it down into fragments and fed it into a hand operated granulation device, which was composed of a series of geared, interlocking teeth that could be rotated using a lever arm. The plastic underwent several phases of repeated grinding, after which it was put through a mesh sieve.

The researchers then created their own melt extrusion device, which they named the Ecostruder. The system uses a single screw system and is powered by an internally geared DC motor.

“To ensure that the screw operates at a constant RPM, an encoder is used to measure the rotational velocity, and which is feedback into a PID controller,” the researchers explain. “The screw is also coupled directly to the geared motor, which provides a simple and robust interface where auxiliary chains are not required. Three individually controlled 50W band heaters provide the ability vary the temperature distribution along the barrel, which in turn allows for control of how the fed waste plastic transitions from solid to the liquid phases.”

Once the filament was generated by the Ecostruder, it was 3D printed using a LulzBot Mini. To make the entire process even more eco-friendly, the researchers used a nanogrid system powered by solar energy, via portable photovoltaic (PV) panels.

“In an ideal scenario, the system which we aimed to create would have the capacity to operate solely from the use of the energy generated by the PV’s,” the researchers state. “This would not be realistic in real operational scenarios and so the aim was to create a dynamic system that could operate directly utilising the energy from the PV cells, and divert excess charge to the lithium-ion batteries. Conversely, in times when insufficient electricity is generated to power a respective device, charge from the battery system can be utilised to sustain operations.”

Tests were performed on the nanogrid system to evaluate its charge generation efficiency. Test 1 was performed on a cloudy day, and Test 2 on a sunny day. The average sustained power output was approximately 14W for test 1 and 210W for test 2. Future modifications of the system may include building larger banks of batteries to store excess charge during times of peak generation, for use on days when power generation is suboptimal.

To test the 3D printing performance of the system, the researchers took it to a location with clear exposure to the sun and 3D printed three different parts: a 20x20x20mm cube, a 30mm diameter and 30mm height cylinder and a lattice structure with a cube of 30x30x30mm. The test was completed in approximately 90 minutes, and the solar panels not only adequately powered the 3D printer but held an excess of energy.

“If we assume the same environmental conditions over a typical day of operation, which would comprise running the 3D printer for 8 hours and the Ecostruder for 2 hours, the generated excess energy would accommodate this usage whilst also charging the battery system by an additional 25Ah,” the researchers state.

Tests were also performed to evaluate the quality of the 3D printed recycled material. To do this, the researchers 3D printed a pipe connector. There were a few cosmetic surface defects, but the part was robust. The researchers used the printed part to join a section of piping, and tested it by blocking the end of one piece of tubing, pressurizing the system using a plumbing pressure testing device. The part held the water with no leakage up to a pressure of 5Bar. The results show that the recycled ABS can be used to 3D print functional parts.

Future studies aim to test the system in field conditions to assess its potential for humanitarian aid.

Authors of the paper include Mazher Iqbal Mohammed, Daniel Wilson, Eli Gomez-Kervin, Callum Vidler, Lucas Rosson and Johannes Long.

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