Technical pathways for distributed recycling of polymer composites for distributed manufacturing: Windshield wiper blades

Dertinger, Samantha C.; Gallup, Nicole; Tanikella, Nagendra Gautam; Grasso, Marzio; Vahid, Samireh; Foot, P.J.S.; Pearce, Joshua M.

doi:10.1016/j.resconrec.2020.104810

Cited by 73 publications

(46 citation statements)

References 69 publications

(55 reference statements)

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“…4. Uses FFF instead of FPF/FGF, the latter of which can make use of far lesscostly feedstocks such as pellets [71][72][73][74][75][76] and is more easily adapted for recycled 3-D printing [77][78][79][80][81].…”

Section: Machine Capabilities Future Work and Conclusionmentioning

confidence: 99%

Open Source High-Temperature RepRap for 3-D Printing Heat-Sterilizable PPE and Other Applications

Skrzypczak¹,

Tanikella²,

Pearce³

2020

Preprint

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Thermal sterilization is generally avoided for 3-D printed components because of the relatively low deformation temperatures for common thermoplastics used for material extrusion-based additive manufacturing. 3-D printing materials required for high-temperature heat sterilizable components for COVID-19 and other applications demands 3-D printers with heated beds, hot ends that can reach higher temperatures than polytetrafluoroethylene (PTFE) hot ends and heated chambers to avoid part warping and delamination. There are several high temperature printers on the market, but their high costs make them inaccessible for full home-based distributed manufacturing required during pandemic lockdowns. To allow for all these requirements to be met for under $1,000, the Cerberus – an open source three-headed self-replicating rapid prototyper (RepRap) was designed and tested with the following capabilities: i) 200oC-capable heated bed, ii) 500oC-capabel hot end, iii) isolated heated chamber with 1kW space heater core and iv) mains voltage chamber and bed heating for rapid start. The Cereberus successfully prints polyetherketoneketone (PEKK) and polyetherimide (PEI, ULTEM) with tensile strengths of 77.5 and 80.5 MPa, respectively. As a case study, open source face masks were 3-D printed in PEKK and shown not to warp upon widely home-accessible oven-based sterilization.

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Section: Machine Capabilities Future Work and Conclusionmentioning

confidence: 99%

Open Source High-Temperature RepRap for 3-D Printing Heat-Sterilizable PPE and Other Applications

Skrzypczak¹,

Tanikella²,

Pearce³

2020

Preprint

Self Cite

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“…In all cases, the designs are evaluated to determine if they can be completely digitally manufactured, ideally from locally-sourced waste products. In some instances, using distributed recycling and additive manufacturing (DRAM) [109][110][111][112][113][114] is possible as the technologies (open source granulator [115], pelletizer [116], and recyclebot (an automated device to make filament for fused filament fabrication-based material extrusion 3-D printing) [117][118][119]) are already mature for pure polymers [109,[120][121][122][123][124][125] and complex plastic packaging, blends and composites [126][127][128][129][130]. In addition, direct material extrusion of waste is now possible for additive manufacturing [113,[131][132][133][134][135][136].…”

Section: Introductionmentioning

confidence: 99%

Distributed Manufacturing of Open-Source Medical Hardware for Pandemics

Pearce¹

2020

Preprint

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Distributed digital manufacturing offers a solution to medical supply and technology shortages during pandemics. To prepare for the next pandemic, this study reviews the state-of-the-art for open hardware designs needed in a COVID-19-like pandemic. It evaluates the readiness of the top twenty technologies requested by the Government of India. The results show that the majority of the actual medical products have had some open source development, however, only 15% of the supporting technologies that make the open source device possible are freely available. The results show there is still considerable work needed to provide open source paths for the development of all the medical hardware needed during pandemics. Five core areas of future work are discussed that include: i) technical development of a wide-range of open source solutions for all medical supplies and devices, ii) policies that protect the productivity of laboratories, makerspaces and fabrication facilities during a pandemic, as well as iii) streamlining the regulatory process, iv) developing Good-Samaritan laws to protect makers and designers of open medical hardware, as well as to compel those with knowledge that will save lives to share it, and v) requiring all citizen-funded research to be released with free and open source licenses.

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“…This limits the recycling cycles to approximately five [ 29 ] before reinforcement or blending with virgin materials becomes necessary. Polymer composites using carbon-reinforced plastic [ 43 ], fiber-filled composites [ 44 , 45 ], and various types of waste wood [ 46 , 47 ] have been used in recyclebot systems, and more complex DRAM systems can use 3D-printed PC as molds for intrusion molding [ 40 ] for windshield wiper composites [ 48 ] as well as Acrylonitrile Styrene Acrylate (ASA) and stamp sand waste composites [ 49 ]. Zander et al [ 50 ] has studied PET, PP, and PS blends with Styrene Ethylene Butylene Styrene (SEBS) and maleic anhydride compatibilizers that were able to increase tensile strength from 19 to 23 MPa, although pure recycled PET had the highest tensile strength of 35 MPa.…”

Section: Introductionmentioning

confidence: 99%

Towards Distributed Recycling with Additive Manufacturing of PET Flake Feedstocks

et al. 2020

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This study explores the potential to reach a circular economy for post-consumer Recycled Polyethylene Terephthalate (rPET) packaging and bottles by using it as a Distributed Recycling for Additive Manufacturing (DRAM) feedstock. Specifically, for the first time, rPET water bottle flake is processed using only an open source toolchain with Fused Particle Fabrication (FPF) or Fused Granular Fabrication (FGF) processing rather than first converting it to filament. In this study, first the impact of granulation, sifting, and heating (and their sequential combination) is quantified on the shape and size distribution of the rPET flakes. Then 3D printing tests were performed on the rPET flake with two different feed systems: an external feeder and feed tube augmented with a motorized auger screw, and an extruder-mounted hopper that enables direct 3D printing. Two Gigabot X machines were used, each with the different feed systems, and one without and the latter with extended part cooling. 3D print settings were optimized based on thermal characterization, and both systems were shown to 3D print rPET directly from shredded water bottles. Mechanical testing showed the importance of isolating rPET from moisture and that geometry was important for uniform extrusion. The mechanical strength of 3D-printed parts with FPF and inconsistent flow is lower than optimized fused filament, but adequate for a wide range of applications. Future work is needed to improve consistency and enable water bottles to be used as a widespread DRAM feedstock.

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Technical pathways for distributed recycling of polymer composites for distributed manufacturing: Windshield wiper blades

Cited by 73 publications

References 69 publications

Open Source High-Temperature RepRap for 3-D Printing Heat-Sterilizable PPE and Other Applications

Open Source High-Temperature RepRap for 3-D Printing Heat-Sterilizable PPE and Other Applications

Distributed Manufacturing of Open-Source Medical Hardware for Pandemics

Towards Distributed Recycling with Additive Manufacturing of PET Flake Feedstocks

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