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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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Penn State Startup Trimatis LLC Hopes to Help the Planet with Recycled Filament

(L to R) Jason Lehrer, Marietta Scanlon and Tito Orjih [Image: Trimatis via Facebook]

A common concern with 3D printing is how efficient it really is. The technology can produce parts locally saving on CO2 when compared to other technologies that have to be centralized. 3D printing also potentially creates parts that use up less material since the process builds the part up as needed along with perhaps some support. This in contrast to other technologies that cut away large amounts of material to create parts. What if we could make it greener and more efficient still? What if we could use plastic waste to make 3D printed parts? There are plenty of conscientious people out there, from startups to the military, putting forth efforts to create ways to reuse and recycle that waste plastic. There’s always a need for more recycling resources in the 3D printing world, and startup Trimatis LLC is ready to help.

Trimatis was formed at Penn State University by recent mechanical engineering graduate Jason Lehrer, current electro-mechanical engineering technology student Tito E. Orjih, and engineering faculty member Marietta R. Scanlon. The three of them were inspired to create the startup after seeing how much waste 3D printers generated – as well as how much waste was on the streets of Philadelphia.

“During my environmental stewardship internship, I witnessed a copious amount of plastic waste littering the streets of Philadelphia,” said Orjih. “Where people saw trash, I saw an opportunity to build a business and help the environment.”

After starting the company, Orjih and Lehrer applied for the 2018 PennTap Inc.U competition.

“We had to turn an idea that was proven in a lab into a business in a short period of time,” said Lehrer. “A lot of time was spent looking into the market to see if this would be a viable business.”

“We prepared by doing a lot of pitch practices in front of different people with different perspectives,” Orjih added. “Each practice pitch helped us address our mistakes and helped us understand how to adjust our pitch based on the audience.”

Penn State President Eric Barron, right, awards $2,000 at the 2018 Invent Penn State Venture & IP Conference to Orjih and Lehrer. [Image: Penn State]

After Inc.U, the pair pitched the company at the 2018 Invent Penn State Venture and IP Conference.

“Another humbling experience,” Orjih said. “The best part was networking with people from the crowd who generally loved what we were doing and wanted to support us.”

Invent Penn State has allowed many students to get businesses off the ground; in the past three years 21 innovation hubs have been funded in Pennsylvania as part of the initiative.

“The education and resources Penn State has provided have been instrumental to the development of the company,” said Scanlon. “The research Jason conducted during his participation in the Multi-Campus REU program sparked the idea. In addition, the Langan Launchbox, Penn State Berks’ innovation hub funded by the Invent Penn State grant, has provided countless resources to ensure the team’s success.”

Trimatis was recently selected as one of 10 finalists in the Great Social Enterprise Pitch, an idea incubator and business plan competition for startups aiming for a positive social or environmental impact. Trimatis has been participating in the incubator all summer and is now in the crowdfunding part of the competition.

[Image: Trimatis via Facebook]

“We plan to keep progressing, improving on our process, marketing and developing connections with people who will be assets to the company,” said Lehrer.

“Our eyes are on the official launch day,” Orjih said. “Our goal is to launch by Jan. 31, so we are taking the proper steps needed to finally be in business.”

If you’d like to support Trimatis, you can check out its crowdfunding campaign on Indiegogo.

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[Source: Penn State]

 

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Military Researchers Present Work on Recycled 3D Printing Material

[Image: Nicole Zander, Army Research Laboratory]

The US military has made no secret of its enthusiasm for 3D printing, and lately has taken a creative, eco-friendly approach to the technology, looking into the recycling of water bottles for 3D printing material. Using water bottles, cardboard and other materials found on base for 3D printing could help reduce dependence on outside supply chains, improve operational readiness and offer greater safety. Normally, soldiers at remote bases or on the battlefield have to wait weeks for replacement parts, but by 3D printing them instead from materials that are readily at hand, they could eliminate that waiting time and become more self-sufficient.

The military researchers presented their work this week at the 256th National Meeting & Exposition of the American Chemical Society.

“Ideally, soldiers wouldn’t have to wait for the next supply truck to receive vital equipment,” said Nicole Zander, PhD. “Instead, they could basically go into the cafeteria, gather discarded water bottles, milk jugs, cardboard boxes and other recyclable items, then use those materials as feedstocks for 3D printers to make tools, parts and other gadgets.”

According to the US Government Accountability Office, the Department of Defense has an inventory of 5 million items distributed through eight supply chains in order to keep military personnel supplied with food, fuel, ammunition and spare parts. Few of these items are stockpiled at front-line locations, however, meaning that shortages can occur at critical times. Many of these front-line locations do have 3D printers, but they often have to wait an extended period of time for feedstock to be replenished.

Nicole Zander, ARL, demonstrates equipment for Capt. Anthony Molnar, U.S. Marine Corps. [Image: Jhi Scott/US Army]

Zander, along with Marine Corps Captain Anthony Molnar and colleagues at the US Army Research Laboratory, has been investigating recycling PET plastic, which is commonly found in water and soda bottles. They determined that filament produced from recycled PET was just as strong as commercially available 3D printer filament. The team used the recycled PET filament to 3D print a vehicle radio bracket, which normally has a long lead time. The process required about 10 water bottles and took about two hours to 3D print.

Originally, the researchers found that other types of plastic, like polypropylene (PP), which is found in yogurt and cottage cheese containers, and polystyrene (PS), used in plastic utensils, were not practical for 3D printing, but some tinkering made them more useful. They strengthened the PP by mixing it with cardboard, wood fibers and other cellulose waste materials, and they also blended PS with PP to make a strong and flexible filament.

The team used a process called solid-state shear pulverization to create composite PP/cellulose materials. Shredded plastic and paper, cardboard or wood flour was pulverized in a twin-screw extruder to generate a fine powder, which was then melted and processed into filament. The researchers tested the new composites and discovered that they had improved mechanical properties that could be used to 3D print strong objects.

Zander and her team are building a mobile recycling center that will allow trained soldiers to make 3D printing filaments out of plastic waste. They are also looking into ways to 3D print from plastic pellets instead of filament, which could allow for the printing of larger objects.

“We still have a lot to learn about how to best process these materials and what kinds of additives will improve their properties,” Zander said. “We’re just scratching the surface of what we can ultimately do with these discarded plastics.”

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