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---
title: Add interchangable patterns to injection moulds
slug: add-interchangable-patterns-to-injection-moulds
description: Utilize lasercut, CNC milled, or handmade plates to incorporate interchangeable text or patterns into injection mold products, including the addition of plastic types or logos.
tags: ["hack","mould","injection"]
category: Guides
difficulty: Medium
time: < 1 week
keywords: laser cutting, CNC milling, interchangeable plates, injection mold products, hexagon tile mold, acrylic plates, aluminum plates, HDPE injection, 3D file requirements, Fusion 360
location: Leuven, Belgium
---
# Add interchangable patterns to injection moulds
![Add interchangable patterns to injection moulds](Luminus-Sheep-on-wheels-2.jpg)
Utilize lasercut, CNC milled, or handmade plates to incorporate interchangeable text or patterns into injection mold products, including the addition of plastic types or logos.
User Location: Leuven, Belgium
## Steps
### Step 1: Have a mould
We are extending an existing mold, specifically a hexagon tile mold. It consists of a three-part flat mold fastened with bolts. Outer dimensions are 15 cm x 15 cm (approx. 6 in x 6 in). The top and bottom plates are 10 mm (approx. 0.4 in) thick, and the center part with the hexagon cutout is 4 mm (approx. 0.16 in) thick.
We will explain the processes of laser cutting and CNC milling. To access these devices, you might inquire at local facilities such as a Fablab or makerspace, or educational institutions.
For laser cut add-ons, we use 4 mm (approx. 0.16 in) acrylic plates sized 15 cm x 15 cm (approx. 6 in x 6 in). For CNC machining, we use 3 mm (approx. 0.12 in) aluminum plates also sized 15 cm x 15 cm.
![Screenshot 2020-02-01 at 15.28.06.png](./Screenshot_2020-02-01_at_15.28.06.png)
![IMG_5319 copy.jpg](./IMG_5319_copy.jpg)
### Step 2: Design a pattern
Certainly.
---
We utilized software to design various patterns. Ensure the text is mirrored when creating a negative. The export format may vary based on your chosen technique.
Additional information, such as plastic type and production details, can be included as needed.
Laser cutting allows for unlimited shapes, though finer details are more challenging. Our experience shows HDPE injection can handle details as small as 0.08-0.12 inches (2-3 mm).
For CNC milling, the detail is limited by the router bit diameter, which rounds corners. Verify the specifications of your machine. We used a 0.04-inch (1 mm) CNC router bit.
![sheeponweels-injection-mould-1-1.jpg](./sheeponweels-injection-mould-1-1.jpg)
![sheeponweels-injection-mould-1-2.jpg](./sheeponweels-injection-mould-1-2.jpg)
### Step 3: Create a compatible file
A 2D file suffices for laser cutting, with PNG and AI formats commonly accepted by various software programs.
For CNC milling, a 3D file is necessary. Software such as Fusion 360 can convert vector files into 3D shapes.
In our example, the cutting depth is set to 1.5 millimeters (0.059 inches).
![Screenshot 2020-05-15 at 11.34.57.png](./Screenshot_2020-05-15_at_11.34.57.png)
### Step 4: Lasercut
### Laser Cutter Settings for Acrylic Moulds
The settings for your cutter will vary based on the type of machine. It is advisable to perform test cuts and adjust the laser's speed and intensity accordingly.
Though acrylic can be safely cut, it does emit an odor; therefore, dust extraction is recommended.
Ensure the pattern is not fully cut through the acrylic plate to preserve the mould's durability, except for certain shapes where this might be acceptable.
Ensure edges are fully cut to avoid the necessity of manual drilling and cutting later. You can assign different settings to cutting lines to achieve multiple depths in one mould.
![sheeponweels-injection-mould-4.jpg](./sheeponweels-injection-mould-4.jpg)
![sheeponweels-injection-mould-8.jpg](./sheeponweels-injection-mould-8.jpg)
![IMG_5703 copy.jpg](./IMG_5703_copy.jpg)
### Step 5: CNC milling
Process the file with the software, secure the material, and begin milling.
Conduct speed tests beforehand.
![sheeponweels-injection-mould-5-1.jpg](./sheeponweels-injection-mould-5-1.jpg)
![sheeponweels-injection-mould-5-2.jpg](./sheeponweels-injection-mould-5-2.jpg)
### Step 6: Inject
Insert the texture plate into the mold and begin injecting.
For optimal results, cool the mold rapidly.
![IMG_5014 copy.jpg](./IMG_5014_copy.jpg)
![sheeponweels-injection-mould-6.jpg](./sheeponweels-injection-mould-6.jpg)
## Resources
### Tools & Equipment
- [Laser Cutter](https://www.fablab-leuven.be/) (e.g., Fab Lab Leuven)
- [CNC Milling Machine](https://www.kuleuven.be/english) (e.g., KU Leuven workshops)
- Injection molding machine
- 4 mm acrylic plates (15 cm x 15 cm)
- 3 mm aluminum plates (15 cm x 15 cm)
### Software
- [Autodesk Fusion 360](https://www.autodesk.com/products/fusion-360/) (3D modeling for CNC)
- [Adobe Illustrator](https://www.adobe.com/products/illustrator.html) (vector design for laser cutting)
- Laser cutter control software (e.g., RDWorks or machine-specific)
- CNC machine control software (e.g., Mach3, GRBL)
### Materials
- HDPE plastic pellets (for injection molding)
- Acrylic sheets (4 mm thickness)
- Aluminum sheets (3 mm thickness)
- Cooling system (water or air-based for rapid mold cooling)
- Bolts (for mold assembly)
### Design Files
- 2D vector files (PNG/AI formats for laser cutting)[1][5]
- 3D CAD files (for CNC milling)[5][6]
- Mirrored text/patterns (negative design)[3]
- Cutting depth specification (1.5 mm for CNC)[6]
- Multi-depth laser engraving settings[5]
### Safety & Maintenance
- ~~[Dust extraction system](https://www.fablab-leuven.be/facilities)~~ (for laser cutting acrylic)[4]
- Test cuts (calibration for laser/CNC settings)[4][6]
- CNC Router bit verification (≥1 mm diameter for CNC)[6]
- Material clamping tools (vice or vacuum table)
- Protective gear (goggles, gloves during injection)[4]
Local fabrication options in Leuven include Fab Lab Leuven for laser cutting/CNC access and KU Leuven’s engineering workshops[2].
## References
## Articles
- [Everything You Need to Know About CNC Machining for Injection Mold Making](https://www.mastercam.com/news/blog/everything-you-need-to-know-about-cnc-machining-for-injection-mold-making/)
- [Intro to Plastic Injection Mold Making](https://www.paulsonmfg.com/blog/intro-to-plastic-injection-mold-making/)
- [A Beginner's Guide to Injection Molding](https://www.protolabs.com/resources/guides-and-trend-reports/designing-for-moldability-fundamental-elements/)
## Books
- *Runner and Gating Design Handbook Second Edition: Tools for Successful Injection Molding* (John Beaumont): [Link](https://www.beaumontinc.com/about/books-by-beaumont/)
- *Successful Injection Molding: Process, Design, and Simulation* (John Beaumont): [Link](https://www.beaumontinc.com/about/books-by-beaumont/)
## Papers
- [Effect of Femtosecond-Laser-Structured Injection Molding Tool on Mechanical Properties](https://pmc.ncbi.nlm.nih.gov/articles/PMC8272158/)
- ~~[Enhancement of Low-Power CO₂ Laser Cutting for Injection-Molded Polycarbonate](https://pure.northampton.ac.uk/files/37975388/Moradi_et_OLT_2017_Enhancement_of_low_power_CO2_laser_cutting_process_for_injection_molded_polycarbonate.pdf)~~
## YouTube
- [Laser Model Making Basics Tutorial Guide](https://www.youtube.com/watch?v=17Pg3QJk00o)
## Open-Source Designs
- [Step-by-Step Laser-Cut Molds for Thermoforming (Instructables)](https://www.instructables.com/Laser-Cut-Forms-for-Thermoforming-Vacuum-Forming/)
- [Fab Academy Week 13 Assignment: Mold Fabrication](https://fabacademy.org/2024/labs/chaihuo/students/matthew-yu/docs/week13_assignment)
- [Soft Robotics Toolkit: Laser-Cutting Mold Parts](https://softroboticstoolkit.com/laser-cut-molds/mold-fabrication/laser-cutting)
## Manufacturer Guides
- [Plastic Injection Mold Making (CS Tool Engineering)](https://www.cste.com/services/plastic-injection-mold-making)
- [Injection Molding vs CNC Machining (3ERP)](https://www.3erp.com/blog/injection-molding-vs-cnc-machining/)

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---
title: Add interchangable patterns to injection moulds
slug: add-interchangable-patterns-to-injection-moulds
description: Utilize lasercut, CNC milled, or handmade plates to incorporate interchangeable text or patterns into injection mold products, including the addition of plastic types or logos.
tags: ["hack","mould","injection"]
category: Guides
difficulty: Medium
time: < 1 week
location: Leuven, Belgium
---
import { Image } from 'astro:assets'
# Add interchangable patterns to injection moulds
<Image src={import('./Luminus-Sheep-on-wheels-2.jpg')} alt="Add interchangable patterns to injection moulds" />
Utilize lasercut, CNC milled, or handmade plates to incorporate interchangeable text or patterns into injection mold products, including the addition of plastic types or logos.
User Location: Leuven, Belgium
## Steps
### Step 1: Have a mould
We are extending an existing mold, specifically a hexagon tile mold. It consists of a three-part flat mold fastened with bolts. Outer dimensions are 15 cm x 15 cm (approx. 6 in x 6 in). The top and bottom plates are 10 mm (approx. 0.4 in) thick, and the center part with the hexagon cutout is 4 mm (approx. 0.16 in) thick.
We will explain the processes of laser cutting and CNC milling. To access these devices, you might inquire at local facilities such as a Fablab or makerspace, or educational institutions.
For laser cut add-ons, we use 4 mm (approx. 0.16 in) acrylic plates sized 15 cm x 15 cm (approx. 6 in x 6 in). For CNC machining, we use 3 mm (approx. 0.12 in) aluminum plates also sized 15 cm x 15 cm.
<Image src={import('./Screenshot_2020-02-01_at_15.28.06.png')} alt="Screenshot 2020-02-01 at 15.28.06.png" />
<Image src={import('./IMG_5319_copy.jpg')} alt="IMG_5319 copy.jpg" />
### Step 2: Design a pattern
Certainly.
---
We utilized software to design various patterns. Ensure the text is mirrored when creating a negative. The export format may vary based on your chosen technique.
Additional information, such as plastic type and production details, can be included as needed.
Laser cutting allows for unlimited shapes, though finer details are more challenging. Our experience shows HDPE injection can handle details as small as 0.08-0.12 inches (2-3 mm).
For CNC milling, the detail is limited by the router bit diameter, which rounds corners. Verify the specifications of your machine. We used a 0.04-inch (1 mm) CNC router bit.
<Image src={import('./sheeponweels-injection-mould-1-1.jpg')} alt="sheeponweels-injection-mould-1-1.jpg" />
<Image src={import('./sheeponweels-injection-mould-1-2.jpg')} alt="sheeponweels-injection-mould-1-2.jpg" />
### Step 3: Create a compatible file
A 2D file suffices for laser cutting, with PNG and AI formats commonly accepted by various software programs.
For CNC milling, a 3D file is necessary. Software such as Fusion 360 can convert vector files into 3D shapes.
In our example, the cutting depth is set to 1.5 millimeters (0.059 inches).
<Image src={import('./Screenshot_2020-05-15_at_11.34.57.png')} alt="Screenshot 2020-05-15 at 11.34.57.png" />
### Step 4: Lasercut
### Laser Cutter Settings for Acrylic Moulds
The settings for your cutter will vary based on the type of machine. It is advisable to perform test cuts and adjust the laser's speed and intensity accordingly.
Though acrylic can be safely cut, it does emit an odor; therefore, dust extraction is recommended.
Ensure the pattern is not fully cut through the acrylic plate to preserve the mould's durability, except for certain shapes where this might be acceptable.
Ensure edges are fully cut to avoid the necessity of manual drilling and cutting later. You can assign different settings to cutting lines to achieve multiple depths in one mould.
<Image src={import('./sheeponweels-injection-mould-4.jpg')} alt="sheeponweels-injection-mould-4.jpg" />
<Image src={import('./sheeponweels-injection-mould-8.jpg')} alt="sheeponweels-injection-mould-8.jpg" />
<Image src={import('./IMG_5703_copy.jpg')} alt="IMG_5703 copy.jpg" />
### Step 5: CNC milling
Process the file with the software, secure the material, and begin milling.
Conduct speed tests beforehand.
<Image src={import('./sheeponweels-injection-mould-5-1.jpg')} alt="sheeponweels-injection-mould-5-1.jpg" />
<Image src={import('./sheeponweels-injection-mould-5-2.jpg')} alt="sheeponweels-injection-mould-5-2.jpg" />
### Step 6: Inject
Insert the texture plate into the mold and begin injecting.
For optimal results, cool the mold rapidly.
<Image src={import('./IMG_5014_copy.jpg')} alt="IMG_5014 copy.jpg" />
<Image src={import('./sheeponweels-injection-mould-6.jpg')} alt="sheeponweels-injection-mould-6.jpg" />

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## Articles
- [Everything You Need to Know About CNC Machining for Injection Mold Making](https://www.mastercam.com/news/blog/everything-you-need-to-know-about-cnc-machining-for-injection-mold-making/)
- [Intro to Plastic Injection Mold Making](https://www.paulsonmfg.com/blog/intro-to-plastic-injection-mold-making/)
- [A Beginner's Guide to Injection Molding](https://www.protolabs.com/resources/guides-and-trend-reports/designing-for-moldability-fundamental-elements/)
## Books
- *Runner and Gating Design Handbook Second Edition: Tools for Successful Injection Molding* (John Beaumont): [Link](https://www.beaumontinc.com/about/books-by-beaumont/)
- *Successful Injection Molding: Process, Design, and Simulation* (John Beaumont): [Link](https://www.beaumontinc.com/about/books-by-beaumont/)
## Papers
- [Effect of Femtosecond-Laser-Structured Injection Molding Tool on Mechanical Properties](https://pmc.ncbi.nlm.nih.gov/articles/PMC8272158/)
- ~~[Enhancement of Low-Power CO₂ Laser Cutting for Injection-Molded Polycarbonate](https://pure.northampton.ac.uk/files/37975388/Moradi_et_OLT_2017_Enhancement_of_low_power_CO2_laser_cutting_process_for_injection_molded_polycarbonate.pdf)~~
## YouTube
- [Laser Model Making Basics Tutorial Guide](https://www.youtube.com/watch?v=17Pg3QJk00o)
## Open-Source Designs
- [Step-by-Step Laser-Cut Molds for Thermoforming (Instructables)](https://www.instructables.com/Laser-Cut-Forms-for-Thermoforming-Vacuum-Forming/)
- [Fab Academy Week 13 Assignment: Mold Fabrication](https://fabacademy.org/2024/labs/chaihuo/students/matthew-yu/docs/week13_assignment)
- [Soft Robotics Toolkit: Laser-Cutting Mold Parts](https://softroboticstoolkit.com/laser-cut-molds/mold-fabrication/laser-cutting)
## Manufacturer Guides
- [Plastic Injection Mold Making (CS Tool Engineering)](https://www.cste.com/services/plastic-injection-mold-making)
- [Injection Molding vs CNC Machining (3ERP)](https://www.3erp.com/blog/injection-molding-vs-cnc-machining/)

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### Tools & Equipment
- [Laser Cutter](https://www.fablab-leuven.be/) (e.g., Fab Lab Leuven)
- [CNC Milling Machine](https://www.kuleuven.be/english) (e.g., KU Leuven workshops)
- Injection molding machine
- 4 mm acrylic plates (15 cm x 15 cm)
- 3 mm aluminum plates (15 cm x 15 cm)
### Software
- [Autodesk Fusion 360](https://www.autodesk.com/products/fusion-360/) (3D modeling for CNC)
- [Adobe Illustrator](https://www.adobe.com/products/illustrator.html) (vector design for laser cutting)
- Laser cutter control software (e.g., RDWorks or machine-specific)
- CNC machine control software (e.g., Mach3, GRBL)
### Materials
- HDPE plastic pellets (for injection molding)
- Acrylic sheets (4 mm thickness)
- Aluminum sheets (3 mm thickness)
- Cooling system (water or air-based for rapid mold cooling)
- Bolts (for mold assembly)
### Design Files
- 2D vector files (PNG/AI formats for laser cutting)[1][5]
- 3D CAD files (for CNC milling)[5][6]
- Mirrored text/patterns (negative design)[3]
- Cutting depth specification (1.5 mm for CNC)[6]
- Multi-depth laser engraving settings[5]
### Safety & Maintenance
- ~~[Dust extraction system](https://www.fablab-leuven.be/facilities)~~ (for laser cutting acrylic)[4]
- Test cuts (calibration for laser/CNC settings)[4][6]
- CNC Router bit verification (≥1 mm diameter for CNC)[6]
- Material clamping tools (vice or vacuum table)
- Protective gear (goggles, gloves during injection)[4]
Local fabrication options in Leuven include Fab Lab Leuven for laser cutting/CNC access and KU Leuven’s engineering workshops[2].

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---
title: Affordable Cat House
slug: affordable-cat-house
description: # How to Draw Custom Shapes and Designs for CNC Cutting
Learn to create unique shapes and designs by hand for CNC machine cutting.
tags: ["HDPE"]
category: Products
difficulty: Medium
time: < 1 day
keywords: CNC cutting, custom shapes design, Rhinoceros 3D, VCarve application, CNC machine cutting, pocketing vs profiling, affordable cat housing, vectorizing drawings, scan filter CamScanner, Istanbul CNC design
location: Istanbul, Turkiye
---
# Affordable Cat House
![Affordable Cat House](_MG_9435-181a5f2baa3.jpg)
# How to Draw Custom Shapes and Designs for CNC Cutting
Learn to create unique shapes and designs by hand for CNC machine cutting.
User Location: Istanbul, Turkiye
## Steps
### Step 1: Draw you design in 1:1 scale
For this initial step, we provided scale documents for drawing. Participants then created their designs. Blue lines indicate pocketing (not cutting through the material), while red lines denote profiling (cutting through the material).
![IMG_1353-181a5f78c5d.PNG](./IMG_1353-181a5f78c5d.PNG)
![IMG_1352-181a5f7c39d.PNG](./IMG_1352-181a5f7c39d.PNG)
### Step 2: Scanning drawings
In this step, we scanned the drawings using a scan filter like CamScanner to ensure a high-contrast image similar to a photocopy.
![Workable Area-1-181a5f969d9.jpg](./Workable_Area-1-181a5f969d9.jpg)
![0001-1-181a5f975e7.jpg](./0001-1-181a5f975e7.jpg)
![0001-181a5f98132.jpg](./0001-181a5f98132.jpg)
### Step 3: Converting drawings into CAD
We used Rhinoceros 3D and the Vectorize plugin to import the drawings as lines in Rhino. We cleaned and simplified the curves using the rebuild command, resulting in smoother curves with fewer control points. Blue lines indicate pocketing, while red lines indicate profiling (cutting through the material).
![Screenshot 2022-06-27 at 19.29.12-181a5ff0df0.png](./Screenshot_2022-06-27_at_19.29.12-181a5ff0df0.png)
### Step 4: Preparing for CNC
For this step, we used the VCarve application. We input the material's width, length, and thickness. We selected the blue lines for 'pocketing' and the red lines for 'profiling'. Note that this step may vary depending on the machine used.
![vcarve_pro_with_nested_polyboard_project-900-181a610c49e.jpeg](./vcarve_pro_with_nested_polyboard_project-900-181a610c49e.jpeg)
### Step 5: CNC miling
In this step, cut the material according to the designs. Secure the four corners of the sheet material to the CNC bed and input the x, y, and z coordinates of the sheet's corner into the CNC machine. Ensure the cutting pattern is correct from an elevated perspective (z coordinates higher than the material) to avoid the CNC bit hitting screws and to confirm that the design fits properly on the sheet without being offset.
![IMG_1356-181a608ed30.jpg](./IMG_1356-181a608ed30.jpg)
![IMG_0607-181a6093bc4.jpg](./IMG_0607-181a6093bc4.jpg)
![IMG_1355-181a609570f.PNG](./IMG_1355-181a609570f.PNG)
### Step 6: Assembly
The final step is to assemble all sides of the Affordable Cat Housing using screws. We used two materials: plastic sheets and OSB panels.
![_MG_9537-181a60b78df.jpg](./_MG_9537-181a60b78df.jpg)
![_MG_9422-181a60bc40b.jpg](./_MG_9422-181a60bc40b.jpg)
![_MG_9452-181a60bf3b5.jpg](./_MG_9452-181a60bf3b5.jpg)
## Resources
### Software
- [CamScanner](https://www.camscanner.com) (high-contrast image scanning)
- [Rhinoceros 3D](https://www.rhino3d.com) with Vectorize plugin (vectorization)
- [VCarve](https://www.vectric.com/products/vcarve-pro) (CNC toolpath programming)
### Hardware
- CNC machine (for cutting operations)
- Screws (securing material to CNC bed and assembly)
### Materials
- Plastic sheets (housing components)
- OSB panels (structural assembly)
## References
## Articles
1. [How to prepare a technical drawing for CNC machining](https://www.hubs.com/knowledge-base/how-prepare-technical-drawing-cnc-machining/)
2. [Fusion 360 CAM for CNC Beginners](https://www.instructables.com/Fusion-360-CAM-Tutorial-for-CNC-Beginners/)
3. [CNC Workflow Using Vectric VCarve Pro](https://makerhardware.net/knowledge-base/how-to-guides/cnc-workflow-using-vectric-vcarve-vcarve-pro-for-cnc/)
4. [Free CNC Software](https://carbide3d.com/learn/free-cnc-software/)
5. [Make Awesome 3D Geometry by Programming CNC-code](https://www.instructables.com/Make-Awesome-3D-Geometry-by-Programming-CNC-code/)
6. [EasyEDA Tutorial](https://image.easyeda.com/files/EasyEDA-Tutorial_v6.4.32.pdf)
## Books
1. [Getting Started with CNC: Personal Digital Fabrication](https://www.harvard.com/book/9781457183362)
2. [Fundamentals of CNC Machining](https://academy.titansofcnc.com/files/Fundamentals_of_CNC_Machining.pdf)
## Papers
1. ~~[Investigating 3 Axis CNC Processes for Creating 3D Objects](https://scholarworks.uark.edu/cgi/viewcontent.cgi?article=1066\&context=inquiry)~~
## YouTube
1. [Vectric V11 Tutorials: Create Shape Guide](https://www.youtube.com/watch?v=1OZVCOYlYy8)
2. [Fusion 360 CNC 3D Carving Tutorial](https://www.youtube.com/watch?v=G3h4Oe2i3Xo)
## Open-source Designs
1. [LinuxCNC Rigid CNC Router](https://www.forum.linuxcnc.org/30-cnc-machines/53486-the-linuxcnc-rigid-CNC Router-an-open-source-dual-z-axis-gantry-machine)

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"text": "For this step, we used the VCarve application. We entered the width, length, and thickness of our material. Then we selected the blue lines and chose 'pocketing' and for the red lines we chose 'profiling'. Every machine is different so this step will be different for everyone. ",
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"text": "This step involves cutting the material according to the designs. For this, we screw four corners of our sheet material to the CNC bed and specify to the CNC machine where are the x, y, and z locations of the corner of the sheet plastic. An important thing to remember is to double-check the cutting pattern from an elevated point (meaning the Z coordinates should be higher than the material) to make sure that the CNC bit is not hitting any of the screws and that the design fits in the sheet nicely and is not offsetted to one side.",
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"title": "CNC miling",
"text": "In this step, cut the material according to the designs. Secure the four corners of the sheet material to the CNC bed and input the x, y, and z coordinates of the sheet's corner into the CNC machine. Ensure the cutting pattern is correct from an elevated perspective (z coordinates higher than the material) to avoid the CNC bit hitting screws and to confirm that the design fits properly on the sheet without being offset.",
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"content": "# How to Draw Custom Shapes and Designs for CNC Cutting\n\nLearn to create unique shapes and designs by hand for CNC machine cutting.\n\n\nUser Location: Istanbul, Turkiye\n\nFor this initial step, we provided scale documents for drawing. Participants then created their designs. Blue lines indicate pocketing (not cutting through the material), while red lines denote profiling (cutting through the material).\n\nIn this step, we scanned the drawings using a scan filter like CamScanner to ensure a high-contrast image similar to a photocopy.\n\nWe used Rhinoceros 3D and the Vectorize plugin to import the drawings as lines in Rhino. We cleaned and simplified the curves using the rebuild command, resulting in smoother curves with fewer control points. Blue lines indicate pocketing, while red lines indicate profiling (cutting through the material).\n\nFor this step, we used the VCarve application. We input the material's width, length, and thickness. We selected the blue lines for 'pocketing' and the red lines for 'profiling'. Note that this step may vary depending on the machine used.\n\nIn this step, cut the material according to the designs. Secure the four corners of the sheet material to the CNC bed and input the x, y, and z coordinates of the sheet's corner into the CNC machine. Ensure the cutting pattern is correct from an elevated perspective (z coordinates higher than the material) to avoid the CNC bit hitting screws and to confirm that the design fits properly on the sheet without being offset.\n\nThe final step is to assemble all sides of the Affordable Cat Housing using screws. We used two materials: plastic sheets and OSB panels.",
"keywords": "CNC cutting, custom shapes design, Rhinoceros 3D, VCarve application, CNC machine cutting, pocketing vs profiling, affordable cat housing, vectorizing drawings, scan filter CamScanner, Istanbul CNC design",
"resources": "### Software\n\n- [CamScanner](https://www.camscanner.com) (high-contrast image scanning)\n- [Rhinoceros 3D](https://www.rhino3d.com) with Vectorize plugin (vectorization)\n- [VCarve](https://www.vectric.com/products/vcarve-pro) (CNC toolpath programming)\n\n### Hardware\n\n- CNC machine (for cutting operations)\n- Screws (securing material to CNC bed and assembly)\n\n### Materials\n\n- Plastic sheets (housing components)\n- OSB panels (structural assembly)",
"references": "## Articles\n\n1. [How to prepare a technical drawing for CNC machining](https://www.hubs.com/knowledge-base/how-prepare-technical-drawing-cnc-machining/)\n2. [Fusion 360 CAM for CNC Beginners](https://www.instructables.com/Fusion-360-CAM-Tutorial-for-CNC-Beginners/)\n3. [CNC Workflow Using Vectric VCarve Pro](https://makerhardware.net/knowledge-base/how-to-guides/cnc-workflow-using-vectric-vcarve-vcarve-pro-for-cnc/)\n4. [Free CNC Software](https://carbide3d.com/learn/free-cnc-software/)\n5. [Make Awesome 3D Geometry by Programming CNC-code](https://www.instructables.com/Make-Awesome-3D-Geometry-by-Programming-CNC-code/)\n6. [EasyEDA Tutorial](https://image.easyeda.com/files/EasyEDA-Tutorial_v6.4.32.pdf)\n\n## Books\n\n1. [Getting Started with CNC: Personal Digital Fabrication](https://www.harvard.com/book/9781457183362)\n2. [Fundamentals of CNC Machining](https://academy.titansofcnc.com/files/Fundamentals_of_CNC_Machining.pdf)\n\n## Papers\n\n1. ~~[Investigating 3 Axis CNC Processes for Creating 3D Objects](https://scholarworks.uark.edu/cgi/viewcontent.cgi?article=1066\\&context=inquiry)~~\n\n## YouTube\n\n1. [Vectric V11 Tutorials: Create Shape Guide](https://www.youtube.com/watch?v=1OZVCOYlYy8)\n2. [Fusion 360 CNC 3D Carving Tutorial](https://www.youtube.com/watch?v=G3h4Oe2i3Xo)\n\n## Open-source Designs\n\n1. [LinuxCNC Rigid CNC Router](https://www.forum.linuxcnc.org/30-cnc-machines/53486-the-linuxcnc-rigid-CNC Router-an-open-source-dual-z-axis-gantry-machine)"
}

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---
title: Affordable Cat House
slug: affordable-cat-house
description: # How to Draw Custom Shapes and Designs for CNC Cutting
Learn to create unique shapes and designs by hand for CNC machine cutting.
tags: ["HDPE"]
category: Products
difficulty: Medium
time: < 1 day
location: Istanbul, Turkiye
---
import { Image } from 'astro:assets'
# Affordable Cat House
<Image src={import('./_MG_9435-181a5f2baa3.jpg')} alt="Affordable Cat House" />
# How to Draw Custom Shapes and Designs for CNC Cutting
Learn to create unique shapes and designs by hand for CNC machine cutting.
User Location: Istanbul, Turkiye
## Steps
### Step 1: Draw you design in 1:1 scale
For this initial step, we provided scale documents for drawing. Participants then created their designs. Blue lines indicate pocketing (not cutting through the material), while red lines denote profiling (cutting through the material).
<Image src={import('./IMG_1353-181a5f78c5d.PNG')} alt="IMG_1353-181a5f78c5d.PNG" />
<Image src={import('./IMG_1352-181a5f7c39d.PNG')} alt="IMG_1352-181a5f7c39d.PNG" />
### Step 2: Scanning drawings
In this step, we scanned the drawings using a scan filter like CamScanner to ensure a high-contrast image similar to a photocopy.
<Image src={import('./Workable_Area-1-181a5f969d9.jpg')} alt="Workable Area-1-181a5f969d9.jpg" />
<Image src={import('./0001-1-181a5f975e7.jpg')} alt="0001-1-181a5f975e7.jpg" />
<Image src={import('./0001-181a5f98132.jpg')} alt="0001-181a5f98132.jpg" />
### Step 3: Converting drawings into CAD
We used Rhinoceros 3D and the Vectorize plugin to import the drawings as lines in Rhino. We cleaned and simplified the curves using the rebuild command, resulting in smoother curves with fewer control points. Blue lines indicate pocketing, while red lines indicate profiling (cutting through the material).
<Image src={import('./Screenshot_2022-06-27_at_19.29.12-181a5ff0df0.png')} alt="Screenshot 2022-06-27 at 19.29.12-181a5ff0df0.png" />
### Step 4: Preparing for CNC
For this step, we used the VCarve application. We input the material's width, length, and thickness. We selected the blue lines for 'pocketing' and the red lines for 'profiling'. Note that this step may vary depending on the machine used.
<Image src={import('./vcarve_pro_with_nested_polyboard_project-900-181a610c49e.jpeg')} alt="vcarve_pro_with_nested_polyboard_project-900-181a610c49e.jpeg" />
### Step 5: CNC miling
In this step, cut the material according to the designs. Secure the four corners of the sheet material to the CNC bed and input the x, y, and z coordinates of the sheet's corner into the CNC machine. Ensure the cutting pattern is correct from an elevated perspective (z coordinates higher than the material) to avoid the CNC bit hitting screws and to confirm that the design fits properly on the sheet without being offset.
<Image src={import('./IMG_1356-181a608ed30.jpg')} alt="IMG_1356-181a608ed30.jpg" />
<Image src={import('./IMG_0607-181a6093bc4.jpg')} alt="IMG_0607-181a6093bc4.jpg" />
<Image src={import('./IMG_1355-181a609570f.PNG')} alt="IMG_1355-181a609570f.PNG" />
### Step 6: Assembly
The final step is to assemble all sides of the Affordable Cat Housing using screws. We used two materials: plastic sheets and OSB panels.
<Image src={import('./_MG_9537-181a60b78df.jpg')} alt="_MG_9537-181a60b78df.jpg" />
<Image src={import('./_MG_9422-181a60bc40b.jpg')} alt="_MG_9422-181a60bc40b.jpg" />
<Image src={import('./_MG_9452-181a60bf3b5.jpg')} alt="_MG_9452-181a60bf3b5.jpg" />

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## Articles
1. [How to prepare a technical drawing for CNC machining](https://www.hubs.com/knowledge-base/how-prepare-technical-drawing-cnc-machining/)
2. [Fusion 360 CAM for CNC Beginners](https://www.instructables.com/Fusion-360-CAM-Tutorial-for-CNC-Beginners/)
3. [CNC Workflow Using Vectric VCarve Pro](https://makerhardware.net/knowledge-base/how-to-guides/cnc-workflow-using-vectric-vcarve-vcarve-pro-for-cnc/)
4. [Free CNC Software](https://carbide3d.com/learn/free-cnc-software/)
5. [Make Awesome 3D Geometry by Programming CNC-code](https://www.instructables.com/Make-Awesome-3D-Geometry-by-Programming-CNC-code/)
6. [EasyEDA Tutorial](https://image.easyeda.com/files/EasyEDA-Tutorial_v6.4.32.pdf)
## Books
1. [Getting Started with CNC: Personal Digital Fabrication](https://www.harvard.com/book/9781457183362)
2. [Fundamentals of CNC Machining](https://academy.titansofcnc.com/files/Fundamentals_of_CNC_Machining.pdf)
## Papers
1. ~~[Investigating 3 Axis CNC Processes for Creating 3D Objects](https://scholarworks.uark.edu/cgi/viewcontent.cgi?article=1066\&context=inquiry)~~
## YouTube
1. [Vectric V11 Tutorials: Create Shape Guide](https://www.youtube.com/watch?v=1OZVCOYlYy8)
2. [Fusion 360 CNC 3D Carving Tutorial](https://www.youtube.com/watch?v=G3h4Oe2i3Xo)
## Open-source Designs
1. [LinuxCNC Rigid CNC Router](https://www.forum.linuxcnc.org/30-cnc-machines/53486-the-linuxcnc-rigid-CNC Router-an-open-source-dual-z-axis-gantry-machine)

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### Software
- [CamScanner](https://www.camscanner.com) (high-contrast image scanning)
- [Rhinoceros 3D](https://www.rhino3d.com) with Vectorize plugin (vectorization)
- [VCarve](https://www.vectric.com/products/vcarve-pro) (CNC toolpath programming)
### Hardware
- CNC machine (for cutting operations)
- Screws (securing material to CNC bed and assembly)
### Materials
- Plastic sheets (housing components)
- OSB panels (structural assembly)

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---
title: Bicycle Shredder V2
slug: bicycle-shredder-v2
description: This tutorial provides an overview of constructing a bicycle shredder. Eighteen months ago, we released a video on building the original bicycle shredder. We have since improved the design and documentation and now present the enhanced second version.
tags: ["hack","shredder"]
category: Machines
difficulty: Very Hard
time: 3-4 weeks
keywords: bicycle shredder, construction tutorial, shredder design, assembly information, high-speed shredding, axle manufacturing, plastic shredding, steel frame construction, workshop safety, human-powered machinery
location: Dresden, Germany
---
# Bicycle Shredder V2
![Bicycle Shredder V2](ND800_0005336_Loehrer.jpg)
This tutorial provides an overview of constructing a bicycle shredder. Eighteen months ago, we released a video on building the original bicycle shredder. We have since improved the design and documentation and now present the enhanced second version.
User Location: Dresden, Germany
## Steps
### Step 1: Get ready!
### Assembly Information for Makers
The download package contains numerous files and drawings. While it may seem overwhelming initially, the following steps provide further insights into the shredder's design. A brief introduction video and an assembly video are forthcoming to enhance understanding of the construction.
[Download Link](https://www.dropbox.com/sh/xlts122wcb905q6/AABRgMZTki8gH1NqQ5SvOS-Ia?dl=0)
![ND800_0005383_freigestellt_Loehrer.jpg](./ND800_0005383_freigestellt_Loehrer.jpg)
### Step 2: Cutting Mill
Most low-speed shredders observed online or within the community tend to be large, heavy, or inefficient. Opting for high-speed shredding utilizes inertia effectively. We chose to shred materials using human-powered high-speed methods.
Various designs exist for constructing the axle. We opted to invest in standard parts to minimize further machining costs. We use span sockets for this reason. However, we recognize these components may not be available in all regions. Explore local resources and capabilities to discover alternative methods for axle manufacturing.
![cutting mill.jpg](./cutting_mill.jpg)
![ND800_0005357_Loehrer.jpg](./ND800_0005357_Loehrer.jpg)
### Step 3: Material Lock
### Shredding Plastic with the Bicycle Shredder
For effective shredding with the bicycle shredder, the cutting mill's knives must rotate at high speed. To safely introduce plastic into the cutting mill without opening it, we initially experimented with various pipe lock designs. However, these proved unreliable, leading us to create a more traditional hopper instead. Although the new hopper is larger and heavier than previous versions, it provides increased stability and safety during operation.
![height adjustment.jpg](./height_adjustment.jpg)
![new material lock.png](./new_material_lock.png)
### Step 4: Sieve and Collection Box
The sieve and collection box are constructed from bent and welded metal sheets. Use a sieve with holes approximately 5-8 mm (3/16-5/16 inches) in diameter. Smaller holes may reduce the plastic to dust. Ensure the metal sheet is of sufficient thickness for stability and the locking system; 1.5 mm (1/16 inch) is recommended.
![collection box sieve.png](./collection_box_sieve.png)
### Step 5: Friction Wheel
The friction wheel transfers speed from the rear wheel to the cutting mill. We make the wheel from plywood because it can be milled using our CNC machine. However, better materials, such as certain plastics, are available for the friction wheel.
![friction wheel.jpg](./friction_wheel.jpg)
### Step 6: Steel Frame
### Steel Frame Construction Guide
Constructing the steel frame necessitates expertise in welding and metalwork. Beginners should consult an experienced metalworker. Use plywood sheet gauges to maintain correct distances between steel tubes and employ large 45° angles to streamline the welding process.
Ensure all holes and slots are drilled and milled into the steel tubes prior to welding, as alignment becomes challenging afterwards.
For welding M16 nuts, align both nuts to properly secure the rear wheel. Use a 14mm (0.55 inches) diameter steel bar for this purpose.
![ND800_0005340_Loehrer.jpg](./ND800_0005340_Loehrer.jpg)
![ND800_0005365_Loehrer.jpg](./ND800_0005365_Loehrer.jpg)
### Step 7: Height Adjustment
Adjusting the height is a simple task. A small steel strip is welded to a clamping ring for the turning knob, and the rest consists of standard components.
![height adjustment.jpg](./height_adjustment.jpg)
### Step 8: Wheel Mount
The wheel-mount involves considerable lathe work but is straightforward. For the turning knob, we cut a piece from a thick metal sheet and welded it to a nut. Alternatively, you can create the knob using steel strips and an angle grinder.
![wheel mount.jpg](./wheel_mount.jpg)
![ND800_0005337_Loehrer.jpg](./ND800_0005337_Loehrer.jpg)
![ND800_0005379_Loehrer.jpg](./ND800_0005379_Loehrer.jpg)
### Step 9: Safety Add-ons
### Workshop Safety Guidelines
Workshops involve diverse participants, and safety is a top priority. We implement a color-coded system for handling equipment:
- **Green:** Accessible to everyone.
- **Orange:** Restricted to team members.
- **Red:** Extremely hazardous; avoid contact.
In addition to our color system, we use standard warning signs and machine-specific instructions. We also install safety features like belt and shaft protections.
Your suggestions for improving machine safety are welcome.
![shaft protection + belt protection.jpg](./shaft_protection_belt_protection.jpg)
## Resources
To build the enhanced bicycle shredder, key components and resources are organized into three main categories, each containing critical elements extracted from the tutorial documentation[1].
### Tools & Workshop Equipment
- Welding equipment (MIG/TIG recommended)
- Lathe (for wheel-mount fabrication)
- Angle grinder (for steel cutting/shaping)
- CNC machine (plywood friction wheel milling)
- Drilling/milling tools (pre-welding preparation)
### Hardware Components
- Steel tubes (14mm diameter bar for frame)
- Span sockets (axle components)
- M16 nuts (rear wheel mounting)
- 1.5mm metal sheets (sieve/collection box)
- Plywood sheets (friction wheel & alignment jigs)
### Software & Documentation
- [Design package](https://www.dropbox.com/sh/xlts122wcb905q6/AABRgMZTki8gH1NqQ5SvOS-Ia?dl=0) (CAD files & technical drawings)
- Assembly video tutorials (forthcoming)
- Sieve specifications (5-8mm holes)
- Metalworking guidelines (bending/welding)
- Safety system documentation (color codes/operational protocols)[1]
Consult the design package and adjust components based on regional availability of materials like span sockets[1]. Prioritize safety protocols during assembly and operation.
## References
## References
### Articles
- *No links provided*
### Books
- *No links provided*
### Papers
- *No links provided*
### YouTube
- *No links provided*
### Opensource Designs
- [Bicycle Shredder Design Files](https://www.dropbox.com/sh/xlts122wcb905q6/AABRgMZTki8gH1NqQ5SvOS-Ia?dl=0)
### Other
- *No links provided*

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---
title: Bicycle Shredder V2
slug: bicycle-shredder-v2
description: This tutorial provides an overview of constructing a bicycle shredder. Eighteen months ago, we released a video on building the original bicycle shredder. We have since improved the design and documentation and now present the enhanced second version.
tags: ["hack","shredder"]
category: Machines
difficulty: Very Hard
time: 3-4 weeks
location: Dresden, Germany
---
import { Image } from 'astro:assets'
# Bicycle Shredder V2
<Image src={import('./ND800_0005336_Loehrer.jpg')} alt="Bicycle Shredder V2" />
This tutorial provides an overview of constructing a bicycle shredder. Eighteen months ago, we released a video on building the original bicycle shredder. We have since improved the design and documentation and now present the enhanced second version.
User Location: Dresden, Germany
## Steps
### Step 1: Get ready!
### Assembly Information for Makers
The download package contains numerous files and drawings. While it may seem overwhelming initially, the following steps provide further insights into the shredder's design. A brief introduction video and an assembly video are forthcoming to enhance understanding of the construction.
[Download Link](https://www.dropbox.com/sh/xlts122wcb905q6/AABRgMZTki8gH1NqQ5SvOS-Ia?dl=0)
<Image src={import('./ND800_0005383_freigestellt_Loehrer.jpg')} alt="ND800_0005383_freigestellt_Loehrer.jpg" />
### Step 2: Cutting Mill
Most low-speed shredders observed online or within the community tend to be large, heavy, or inefficient. Opting for high-speed shredding utilizes inertia effectively. We chose to shred materials using human-powered high-speed methods.
Various designs exist for constructing the axle. We opted to invest in standard parts to minimize further machining costs. We use span sockets for this reason. However, we recognize these components may not be available in all regions. Explore local resources and capabilities to discover alternative methods for axle manufacturing.
<Image src={import('./cutting_mill.jpg')} alt="cutting mill.jpg" />
<Image src={import('./ND800_0005357_Loehrer.jpg')} alt="ND800_0005357_Loehrer.jpg" />
### Step 3: Material Lock
### Shredding Plastic with the Bicycle Shredder
For effective shredding with the bicycle shredder, the cutting mill's knives must rotate at high speed. To safely introduce plastic into the cutting mill without opening it, we initially experimented with various pipe lock designs. However, these proved unreliable, leading us to create a more traditional hopper instead. Although the new hopper is larger and heavier than previous versions, it provides increased stability and safety during operation.
<Image src={import('./height_adjustment.jpg')} alt="height adjustment.jpg" />
<Image src={import('./new_material_lock.png')} alt="new material lock.png" />
### Step 4: Sieve and Collection Box
The sieve and collection box are constructed from bent and welded metal sheets. Use a sieve with holes approximately 5-8 mm (3/16-5/16 inches) in diameter. Smaller holes may reduce the plastic to dust. Ensure the metal sheet is of sufficient thickness for stability and the locking system; 1.5 mm (1/16 inch) is recommended.
<Image src={import('./collection_box_sieve.png')} alt="collection box sieve.png" />
### Step 5: Friction Wheel
The friction wheel transfers speed from the rear wheel to the cutting mill. We make the wheel from plywood because it can be milled using our CNC machine. However, better materials, such as certain plastics, are available for the friction wheel.
<Image src={import('./friction_wheel.jpg')} alt="friction wheel.jpg" />
### Step 6: Steel Frame
### Steel Frame Construction Guide
Constructing the steel frame necessitates expertise in welding and metalwork. Beginners should consult an experienced metalworker. Use plywood sheet gauges to maintain correct distances between steel tubes and employ large 45° angles to streamline the welding process.
Ensure all holes and slots are drilled and milled into the steel tubes prior to welding, as alignment becomes challenging afterwards.
For welding M16 nuts, align both nuts to properly secure the rear wheel. Use a 14mm (0.55 inches) diameter steel bar for this purpose.
<Image src={import('./ND800_0005340_Loehrer.jpg')} alt="ND800_0005340_Loehrer.jpg" />
<Image src={import('./ND800_0005365_Loehrer.jpg')} alt="ND800_0005365_Loehrer.jpg" />
### Step 7: Height Adjustment
Adjusting the height is a simple task. A small steel strip is welded to a clamping ring for the turning knob, and the rest consists of standard components.
<Image src={import('./height_adjustment.jpg')} alt="height adjustment.jpg" />
### Step 8: Wheel Mount
The wheel-mount involves considerable lathe work but is straightforward. For the turning knob, we cut a piece from a thick metal sheet and welded it to a nut. Alternatively, you can create the knob using steel strips and an angle grinder.
<Image src={import('./wheel_mount.jpg')} alt="wheel mount.jpg" />
<Image src={import('./ND800_0005337_Loehrer.jpg')} alt="ND800_0005337_Loehrer.jpg" />
<Image src={import('./ND800_0005379_Loehrer.jpg')} alt="ND800_0005379_Loehrer.jpg" />
### Step 9: Safety Add-ons
### Workshop Safety Guidelines
Workshops involve diverse participants, and safety is a top priority. We implement a color-coded system for handling equipment:
- **Green:** Accessible to everyone.
- **Orange:** Restricted to team members.
- **Red:** Extremely hazardous; avoid contact.
In addition to our color system, we use standard warning signs and machine-specific instructions. We also install safety features like belt and shaft protections.
Your suggestions for improving machine safety are welcome.
<Image src={import('./shaft_protection_belt_protection.jpg')} alt="shaft protection + belt protection.jpg" />

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## References
### Articles
- *No links provided*
### Books
- *No links provided*
### Papers
- *No links provided*
### YouTube
- *No links provided*
### Opensource Designs
- [Bicycle Shredder Design Files](https://www.dropbox.com/sh/xlts122wcb905q6/AABRgMZTki8gH1NqQ5SvOS-Ia?dl=0)
### Other
- *No links provided*

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To build the enhanced bicycle shredder, key components and resources are organized into three main categories, each containing critical elements extracted from the tutorial documentation[1].
### Tools & Workshop Equipment
- Welding equipment (MIG/TIG recommended)
- Lathe (for wheel-mount fabrication)
- Angle grinder (for steel cutting/shaping)
- CNC machine (plywood friction wheel milling)
- Drilling/milling tools (pre-welding preparation)
### Hardware Components
- Steel tubes (14mm diameter bar for frame)
- Span sockets (axle components)
- M16 nuts (rear wheel mounting)
- 1.5mm metal sheets (sieve/collection box)
- Plywood sheets (friction wheel & alignment jigs)
### Software & Documentation
- [Design package](https://www.dropbox.com/sh/xlts122wcb905q6/AABRgMZTki8gH1NqQ5SvOS-Ia?dl=0) (CAD files & technical drawings)
- Assembly video tutorials (forthcoming)
- Sieve specifications (5-8mm holes)
- Metalworking guidelines (bending/welding)
- Safety system documentation (color codes/operational protocols)[1]
Consult the design package and adjust components based on regional availability of materials like span sockets[1]. Prioritize safety protocols during assembly and operation.

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---
title: Bike Pedals & Grips Mould
slug: bike-pedals--grips-mould
description: # How-To: Mold Creation
This tutorial explains how I created the mold. While injecting the pedal is quick, fabricating the mold requires significant time. Milling the mold is recommended if feasible, as welding is time-intensive. The 3D model is available for download to customize your own version.
tags: ["HDPE","injection","mould"]
category: Moulds
difficulty: Medium
time: < 1 day
keywords: Mold creation, injection molding, 3D model download, metal fabrication, welding instructions, plastic materials comparison, pedal fabrication, DIY mold tutorial, safety equipment for welding, metal cutting techniques
location:
---
# Bike Pedals & Grips Mould
![Bike Pedals & Grips Mould](marquage2-18391d70aa8.jpg)
# How-To: Mold Creation
This tutorial explains how I created the mold. While injecting the pedal is quick, fabricating the mold requires significant time. Milling the mold is recommended if feasible, as welding is time-intensive. The 3D model is available for download to customize your own version.
## Steps
### Step 1: Tools
- Injection machine
- Angle grinder (cutting and grinding discs)
- Vise
- Flat file, round file (optional: small rotary tool like a Proxxon or Dremel)
- Drill press
- Clamps (at least 3)
- Welding machine (for pedals) and welding attire
- Radius scriber (or a marker)
- Safety glasses
- Respirator with A1 P1 filter
- Safety gloves
- Ear protection
- Sandpaper (grit around 80) (optional: electric sander)
- Measuring tape
- Square edge
- M6, M8 thread tap
- Drill bit sizes: 4.3 mm (3/16 in), 6.4 mm (1/4 in), 6.8 mm (17/64 in), 8.4 mm (21/64 in), 11 mm (7/16 in), 20 mm (25/32 in), 22.5 mm (7/8 in) (substitute with round file if 22.5 mm unavailable)
- Tweezers (optional, for ball bearings assembly)
![injector.jpg](./injector.jpg)
![anglegrinder.jpg](./anglegrinder.jpg)
![instruments.jpg](./instruments.jpg)
### Step 2: Material for the grips
Plastic materials: Experiments were conducted with polystyrene (PS) and polyethylene (PE). PS appears stronger, but due to the availability of only black PS, PE was used for the presented objects. The pedal has a volume of 8.85 in³ (145 cm³), and the grip is 5.13 in³ (84 cm³).
Components for Grips:
- Metal Tube: Internal diameter should match the desired grip size; larger diameters offer better comfort. Selected diameter: 1.38 in (35 mm). Length should match desired grip length minus 0.12 in (3 mm). Example: For two grips of 5.12 in (130 mm) each, actual length is 5 in (127 mm).
- Metal Sheet: Steel, 0.16 in (4 mm) thick; dimensions 7.09 x 2.36 in (180 x 60 mm).
- Threaded Rod: M6 x 17.72 in (450 mm); M8 x 5.91 in (150 mm).
- Nuts: 6 units, M6.
- Metal Cylinder: Diameter of 0.88 in (22.3 mm), length of 4.37 in (111 mm). Standard handlebars are 0.87 in (22 mm) in diameter, so choose slightly larger.
- Bolt: M8 x 0.79 in (20 mm).
- Washer: M20.
- Nut: M8.
### Step 3: Material for the pedals
- Metal sheet (steel 0.16 in thick; 4.72 x 9.45 in; 1.02 x 27.56 in)
- Welding rod (0.08 or 0.12 in)
- 3 bolts M6 x 10 (any size is suitable with the corresponding drill bits)
- 2 pedal axles with ball bearings, washers, and nuts
- Wood (optional for positioning during welding) (pedal size)
- 4 bolts and nuts M4 x 40 (only length required)
- 24 setscrews M6 x 8
![marquage2.jpg](./marquage2.jpg)
### Step 4: Grip mold: cut the parts
Cut the tube to the desired grip length (5.12 in). Cut four hexagons with 1.30 in sides. Drill three corner holes in each hexagon. In the first, drill a central hexagon with 0.39 in sides. In the second, drill a 0.20 in center hole. In the third, drill a 0.89 in center hole. In the fourth, drill a 0.31 in center hole. Cut three M5 and one M8 threaded rods to 5.91 in. Cut the cylinder to the required length (4.37 in). Make an M8 x 0.79 threaded hole at the center of one cylinder end.
![plaques.jpg](./plaques.jpg)
![marquage.jpg](./marquage.jpg)
### Step 5: Pedal mold: cut the parts
Cut two squares measuring 120 x 120 mm (4.72 x 4.72 inches) from the metal sheet. Drill holes in the four corners with a diameter of 4.3 mm (0.17 inches). Outline the desired pedal shape on one square face. Drill the injection hole at your chosen location, with a recommended diameter of 5 mm (0.2 inches), ideally centered.
Cut a metal band of 26 mm (1.02 inches) height and a minimum of 300 mm (11.81 inches) length, and another band of 26 mm (1.02 inches) height by at least 340 mm (13.39 inches) length. From the 300 mm band, cut segments of 15.6 mm (0.61 inches) (2 pieces); 24 mm (0.94 inches) (2 pieces); 18 mm (0.71 inches) (2 pieces); 33 mm (1.30 inches) (2 pieces); and 25 mm (0.98 inches) (2 pieces). Cut one piece measuring 43.4 mm (1.71 inches).
From the 340 mm band, cut 40 mm (1.57 inches) (2 pieces); 56 mm (2.20 inches) (4 pieces); and 27.7 mm (1.09 inches) (1 piece).
Additionally, cut six small pieces measuring 5 x 10 mm (0.20 x 0.39 inches) to wedge the mold parts. For the triangle and trapezoid center, cut two pieces of 25 x 7 mm (0.98 x 0.28 inches) and one piece of 4 x 35 mm (0.16 x 1.38 inches).
![marquage2.jpg](./marquage2.jpg)
![meulage.jpg](./meulage.jpg)
![plaquettes.jpg](./plaquettes.jpg)
### Step 6: Make the Pedal Mold: Weld It
### Welding Instructions
Before welding, sand each vertical face of the wooden parts (triangle, trapezoids, and pedal) at an angle of approximately 2 degrees to facilitate extraction. I used a sanding machine for this task.
To weld the pedal perimeter, clamp the wooden pedal on your welding surface and secure the edges you plan to weld. Repeat this process with the other parts, ensuring they remain flat against the ground. My initial arc welding attempt yielded less than perfect results, but this only increases the grinding duration.
![serrejoint.jpg](./serrejoint.jpg)
![assemblage.jpg](./assemblage.jpg)
### Step 7: Inject the Grips
1. Turn on the heater.
2. Assemble the cylinder with the base hexagon (No. 4).
3. Insert the three threaded rods.
4. Place the washer around the cylinder.
5. Attach the tube.
6. Install the top hexagon with the injection hole (No. 2).
7. Add the top hexagon with a hexagonal hole (No. 1).
8. Secure with nuts.
9. Fill the machine with plastic.
10. Wait for 5 minutes.
11. Inject.
Remove the grip using the M8 threaded rod and nut.
![moulepoignee.jpg](./moulepoignee.jpg)
![moulepoignee2.jpg](./moulepoignee2.jpg)
![moulepoignee8.jpg](./moulepoignee8.jpg)
### Step 8: Inject the Pedals
Heat the machine (temperature conversion: enter desired temperature in °C or °F).
Fill with old plastic (material volume conversion: kg to lb or vice versa).
Inject.
Open the mold.
![pedalinjection2.jpg](./pedalinjection2.jpg)
![pedalinjection4.jpg](./pedalinjection4.jpg)
![pedalinjection5.jpg](./pedalinjection5.jpg)
### Step 9: Finish and Assembly
Ensure the pedal is firmly positioned in the jig. Attach an 11 mm (7/16 inch) drill bit, aligning it with the pedal center. Secure the jig to the drill and completely drill through the pedal. Switch to a 20 mm (3/4 inch) drill bit and drill 8 mm (5/16 inch) deep on the bike side of the pedal. Flip the pedal and drill 15 mm (5/8 inch) deep on the outer part, measuring from the flat face.
![pedalfinition.jpg](./pedalfinition.jpg)
![pedalfinition3.jpg](./pedalfinition3.jpg)
![pedalfinition4.jpg](./pedalfinition4.jpg)
## Resources
### Tools
- Injection machine
- Angle grinder (cutting and grinding discs)
- Drill press (with 4.3mm–22.5mm bits)
- Welding machine (with protective attire)
- M6/M8 thread taps
### Software
- 3D modeling software (for customizing mold design)
### Hardware
- Steel sheets (4mm thick)
- Metal tubes (35mm internal diameter)
- Threaded rods (M6/M8)
- Assorted nuts/bolts (M4/M6/M8)
- Plastic pellets (PS/PE)
## References
## References
### YouTube
- [Beginner To Advanced — How To Create a Mold— Part 1](https://www.youtube.com/watch?v=_hGMWhde1So) [1]
- [Mold Design for Beginners](https://www.youtube.com/watch?v=hRU_qNr8zLg) [8]
### Articles
- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/) [2]
- [A Step by Step Guide to Injection Molding - SyBridge Technologies](https://sybridge.com/injection-molding-guide/) [5]
### Books
- [Mold Making and Casting Guide Book - ComposiMold.com](https://composimoldstore.com/mold-making-and-casting-guide/) [3]
### Papers
- [Overview of Injection Molding Technology for Processing Polymers (PDF)](https://www.espublisher.com/uploads/article_pdf/esmm5f713.pdf) [4]
### Open-Source Designs
- [Open Source Skateboard Mold - Good Roads Collective](https://www.goodroadscollective.com/open-source-skateboard-mold) [6]

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---
title: Bike Pedals & Grips Mould
slug: bike-pedals--grips-mould
description: # How-To: Mold Creation
This tutorial explains how I created the mold. While injecting the pedal is quick, fabricating the mold requires significant time. Milling the mold is recommended if feasible, as welding is time-intensive. The 3D model is available for download to customize your own version.
tags: ["HDPE","injection","mould"]
category: Moulds
difficulty: Medium
time: < 1 day
location:
---
import { Image } from 'astro:assets'
# Bike Pedals & Grips Mould
<Image src={import('./marquage2-18391d70aa8.jpg')} alt="Bike Pedals & Grips Mould" />
# How-To: Mold Creation
This tutorial explains how I created the mold. While injecting the pedal is quick, fabricating the mold requires significant time. Milling the mold is recommended if feasible, as welding is time-intensive. The 3D model is available for download to customize your own version.
## Steps
### Step 1: Tools
- Injection machine
- Angle grinder (cutting and grinding discs)
- Vise
- Flat file, round file (optional: small rotary tool like a Proxxon or Dremel)
- Drill press
- Clamps (at least 3)
- Welding machine (for pedals) and welding attire
- Radius scriber (or a marker)
- Safety glasses
- Respirator with A1 P1 filter
- Safety gloves
- Ear protection
- Sandpaper (grit around 80) (optional: electric sander)
- Measuring tape
- Square edge
- M6, M8 thread tap
- Drill bit sizes: 4.3 mm (3/16 in), 6.4 mm (1/4 in), 6.8 mm (17/64 in), 8.4 mm (21/64 in), 11 mm (7/16 in), 20 mm (25/32 in), 22.5 mm (7/8 in) (substitute with round file if 22.5 mm unavailable)
- Tweezers (optional, for ball bearings assembly)
<Image src={import('./injector.jpg')} alt="injector.jpg" />
<Image src={import('./anglegrinder.jpg')} alt="anglegrinder.jpg" />
<Image src={import('./instruments.jpg')} alt="instruments.jpg" />
### Step 2: Material for the grips
Plastic materials: Experiments were conducted with polystyrene (PS) and polyethylene (PE). PS appears stronger, but due to the availability of only black PS, PE was used for the presented objects. The pedal has a volume of 8.85 in³ (145 cm³), and the grip is 5.13 in³ (84 cm³).
Components for Grips:
- Metal Tube: Internal diameter should match the desired grip size; larger diameters offer better comfort. Selected diameter: 1.38 in (35 mm). Length should match desired grip length minus 0.12 in (3 mm). Example: For two grips of 5.12 in (130 mm) each, actual length is 5 in (127 mm).
- Metal Sheet: Steel, 0.16 in (4 mm) thick; dimensions 7.09 x 2.36 in (180 x 60 mm).
- Threaded Rod: M6 x 17.72 in (450 mm); M8 x 5.91 in (150 mm).
- Nuts: 6 units, M6.
- Metal Cylinder: Diameter of 0.88 in (22.3 mm), length of 4.37 in (111 mm). Standard handlebars are 0.87 in (22 mm) in diameter, so choose slightly larger.
- Bolt: M8 x 0.79 in (20 mm).
- Washer: M20.
- Nut: M8.
### Step 3: Material for the pedals
- Metal sheet (steel 0.16 in thick; 4.72 x 9.45 in; 1.02 x 27.56 in)
- Welding rod (0.08 or 0.12 in)
- 3 bolts M6 x 10 (any size is suitable with the corresponding drill bits)
- 2 pedal axles with ball bearings, washers, and nuts
- Wood (optional for positioning during welding) (pedal size)
- 4 bolts and nuts M4 x 40 (only length required)
- 24 setscrews M6 x 8
<Image src={import('./marquage2.jpg')} alt="marquage2.jpg" />
### Step 4: Grip mold: cut the parts
Cut the tube to the desired grip length (5.12 in). Cut four hexagons with 1.30 in sides. Drill three corner holes in each hexagon. In the first, drill a central hexagon with 0.39 in sides. In the second, drill a 0.20 in center hole. In the third, drill a 0.89 in center hole. In the fourth, drill a 0.31 in center hole. Cut three M5 and one M8 threaded rods to 5.91 in. Cut the cylinder to the required length (4.37 in). Make an M8 x 0.79 threaded hole at the center of one cylinder end.
<Image src={import('./plaques.jpg')} alt="plaques.jpg" />
<Image src={import('./marquage.jpg')} alt="marquage.jpg" />
### Step 5: Pedal mold: cut the parts
Cut two squares measuring 120 x 120 mm (4.72 x 4.72 inches) from the metal sheet. Drill holes in the four corners with a diameter of 4.3 mm (0.17 inches). Outline the desired pedal shape on one square face. Drill the injection hole at your chosen location, with a recommended diameter of 5 mm (0.2 inches), ideally centered.
Cut a metal band of 26 mm (1.02 inches) height and a minimum of 300 mm (11.81 inches) length, and another band of 26 mm (1.02 inches) height by at least 340 mm (13.39 inches) length. From the 300 mm band, cut segments of 15.6 mm (0.61 inches) (2 pieces); 24 mm (0.94 inches) (2 pieces); 18 mm (0.71 inches) (2 pieces); 33 mm (1.30 inches) (2 pieces); and 25 mm (0.98 inches) (2 pieces). Cut one piece measuring 43.4 mm (1.71 inches).
From the 340 mm band, cut 40 mm (1.57 inches) (2 pieces); 56 mm (2.20 inches) (4 pieces); and 27.7 mm (1.09 inches) (1 piece).
Additionally, cut six small pieces measuring 5 x 10 mm (0.20 x 0.39 inches) to wedge the mold parts. For the triangle and trapezoid center, cut two pieces of 25 x 7 mm (0.98 x 0.28 inches) and one piece of 4 x 35 mm (0.16 x 1.38 inches).
<Image src={import('./marquage2.jpg')} alt="marquage2.jpg" />
<Image src={import('./meulage.jpg')} alt="meulage.jpg" />
<Image src={import('./plaquettes.jpg')} alt="plaquettes.jpg" />
### Step 6: Make the Pedal Mold: Weld It
### Welding Instructions
Before welding, sand each vertical face of the wooden parts (triangle, trapezoids, and pedal) at an angle of approximately 2 degrees to facilitate extraction. I used a sanding machine for this task.
To weld the pedal perimeter, clamp the wooden pedal on your welding surface and secure the edges you plan to weld. Repeat this process with the other parts, ensuring they remain flat against the ground. My initial arc welding attempt yielded less than perfect results, but this only increases the grinding duration.
<Image src={import('./serrejoint.jpg')} alt="serrejoint.jpg" />
<Image src={import('./assemblage.jpg')} alt="assemblage.jpg" />
### Step 7: Inject the Grips
1. Turn on the heater.
2. Assemble the cylinder with the base hexagon (No. 4).
3. Insert the three threaded rods.
4. Place the washer around the cylinder.
5. Attach the tube.
6. Install the top hexagon with the injection hole (No. 2).
7. Add the top hexagon with a hexagonal hole (No. 1).
8. Secure with nuts.
9. Fill the machine with plastic.
10. Wait for 5 minutes.
11. Inject.
Remove the grip using the M8 threaded rod and nut.
<Image src={import('./moulepoignee.jpg')} alt="moulepoignee.jpg" />
<Image src={import('./moulepoignee2.jpg')} alt="moulepoignee2.jpg" />
<Image src={import('./moulepoignee8.jpg')} alt="moulepoignee8.jpg" />
### Step 8: Inject the Pedals
Heat the machine (temperature conversion: enter desired temperature in °C or °F).
Fill with old plastic (material volume conversion: kg to lb or vice versa).
Inject.
Open the mold.
<Image src={import('./pedalinjection2.jpg')} alt="pedalinjection2.jpg" />
<Image src={import('./pedalinjection4.jpg')} alt="pedalinjection4.jpg" />
<Image src={import('./pedalinjection5.jpg')} alt="pedalinjection5.jpg" />
### Step 9: Finish and Assembly
Ensure the pedal is firmly positioned in the jig. Attach an 11 mm (7/16 inch) drill bit, aligning it with the pedal center. Secure the jig to the drill and completely drill through the pedal. Switch to a 20 mm (3/4 inch) drill bit and drill 8 mm (5/16 inch) deep on the bike side of the pedal. Flip the pedal and drill 15 mm (5/8 inch) deep on the outer part, measuring from the flat face.
<Image src={import('./pedalfinition.jpg')} alt="pedalfinition.jpg" />
<Image src={import('./pedalfinition3.jpg')} alt="pedalfinition3.jpg" />
<Image src={import('./pedalfinition4.jpg')} alt="pedalfinition4.jpg" />

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## References
### YouTube
- [Beginner To Advanced — How To Create a Mold— Part 1](https://www.youtube.com/watch?v=_hGMWhde1So) [1]
- [Mold Design for Beginners](https://www.youtube.com/watch?v=hRU_qNr8zLg) [8]
### Articles
- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/) [2]
- [A Step by Step Guide to Injection Molding - SyBridge Technologies](https://sybridge.com/injection-molding-guide/) [5]
### Books
- [Mold Making and Casting Guide Book - ComposiMold.com](https://composimoldstore.com/mold-making-and-casting-guide/) [3]
### Papers
- [Overview of Injection Molding Technology for Processing Polymers (PDF)](https://www.espublisher.com/uploads/article_pdf/esmm5f713.pdf) [4]
### Open-Source Designs
- [Open Source Skateboard Mold - Good Roads Collective](https://www.goodroadscollective.com/open-source-skateboard-mold) [6]

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### Tools
- Injection machine
- Angle grinder (cutting and grinding discs)
- Drill press (with 4.3mm–22.5mm bits)
- Welding machine (with protective attire)
- M6/M8 thread taps
### Software
- 3D modeling software (for customizing mold design)
### Hardware
- Steel sheets (4mm thick)
- Metal tubes (35mm internal diameter)
- Threaded rods (M6/M8)
- Assorted nuts/bolts (M4/M6/M8)
- Plastic pellets (PS/PE)

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@ -0,0 +1,98 @@
---
title: Build a bicycle powered shredder!
slug: build-a-bicycle-powered-shredder
description: ### Tutorial: Constructing a Bicycle-Powered Plastic Shredder
This guide outlines the construction of a bicycle-powered plastic shredder and provides instructions for building your own. The device offers a cost-effective method of shredding plastic without relying on electricity.
**Step 1**: Find detailed construction plans and necessary files.
tags: ["collection","shredder","HDPE"]
category: uncategorized
difficulty: Hard
time: 3-4 weeks
keywords: bicycle-powered plastic shredder, DIY plastic shredder, build plastic shredder, construct bicycle shredder, cost-effective plastic shredding, manual plastic shredding, plastic shredder instructions, shredder construction plans, plastic recycling tools, non-electric shredder
location:
---
# Build a bicycle powered shredder!
![Build a bicycle powered shredder!](COVER_PHOTO.png)
### Tutorial: Constructing a Bicycle-Powered Plastic Shredder
This guide outlines the construction of a bicycle-powered plastic shredder and provides instructions for building your own. The device offers a cost-effective method of shredding plastic without relying on electricity.
**Step 1**: Find detailed construction plans and necessary files.
## Steps
### Step 1: Open the construction manual
Via this link: [drive.google.com](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing), you can access a detailed construction plan, bill of materials, technical drawings, and laser cutting files required to build a bicycle-powered shredder.
Note: The files exceed the maximum allowed size for the supporting files tab.
![CONSTRUCTION MANUAL.png](./CONSTRUCTION_MANUAL.png)
### Step 2: Built or buy the shredder box
The plans for constructing a shredder box are detailed. You can also purchase one.
![Best-of-bike-shredder-15.jpg](./Best-of-bike-shredder-15.jpg)
### Step 3: Built the custom axle
This custom flywheel and axle generate momentum for shredding. It also serves as a base for connecting the gears discussed in step 5. Cutting files and technical drawings are available in the files in step 1.
![Production-43.jpg](./Production-43.jpg)
![Production-53.jpg](./Production-53.jpg)
### Step 4: Shredder stand and container
Construct the shredder stand to provide an elevated platform for the shredded pieces to exit and to ensure safety. Our construction plan outlines potential optimizations based on issues we encountered.
![Production-23.jpg](./Production-23.jpg)
![Production-44.jpg](./Production-44.jpg)
### Step 5: Attaching everything together
The power output is amplified through two ratio transmissions totaling 1:4.6, resulting in 4.6 times more power at a reduced rotational speed. A large gear connects to the shredder box, and a substantial crankset is attached to the custom flywheel.
![transmission 2.png](./transmission_2.png)
![transmission 1.png](./transmission_1.png)
### Step 6: Let's start shredding plastic!
### Shredding Process
With the final setup complete, begin shredding the plastic.
![let's start shredding plastic.png](./lets_start_shredding_plastic.png)
## Resources
### Software Requirements
- Construction plans, bill of materials, and laser cutting files: [drive.google.com](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing)
### Hardware Components
- Shredder box (detailed construction plans)
- Custom flywheel and axle (technical drawings included)
- Shredder stand (optimized for safety and output)
- Gear system (1:4.6 ratio transmission)
- Large crankset (attached to flywheel)
### Tools
- Laser cutter (for fabricating components from cutting files)
## References
## Open-source Designs
- [Bicycle-Powered Plastic Shredder Construction Files](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing)

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"creatorCountry": "",
"_creatorId": "dk",
"creatorName": "dk",
"_created": "2023-02-15T08:42:08.563Z",
"_id": "Lr5lmkSEQ9jFjazk1lDw"
},
{
"_creatorId": "angelrotil",
"creatorName": "angelrotil",
"creatorCountry": "ph",
"_id": "vHkbE8CRUEu0j8YZ4v38",
"text": "Hello! May I know where did you bought your shredder?",
"_created": "2023-09-09T00:20:59.529Z"
},
{
"_created": "2023-09-16T21:32:07.076Z",
"_id": "DBBazICKGdaeu6ite7DI",
"creatorCountry": "de",
"creatorName": "zodachem",
"text": "Hello, do you sell this bicyle shredder ?",
"_creatorId": "zodachem"
},
{
"creatorCountry": "us",
"_creatorId": "mavigogun",
"_created": "2023-12-29T15:00:39.907Z",
"_id": "CdOdIVZpDj8Pyu0gpZZE",
"text": "I can see advantage to orienting the peddler towards the shredder and within easy reach of the intake- a design challenge, for sure, but worthwhile.",
"_edited": "2023-12-29T15:01:05.625Z",
"creatorName": "mavigogun"
},
{
"creatorName": "makerspaceli",
"text": "How much was the cost to build it?",
"_creatorId": "makerspaceli",
"_created": "2024-02-12T13:47:11.057Z",
"_id": "yFclVOusbzVhA1myJxUn",
"creatorCountry": "li"
}
],
"mentions": [],
"tags": [
"collection",
"shredder",
"HDPE"
],
"id": "kd8f9OMFpS50jllLzzvR",
"difficulty_level": "Hard",
"slug": "build-a-bicycle-powered-shredder",
"category": {
"label": "uncategorized"
},
"content": "### Tutorial: Constructing a Bicycle-Powered Plastic Shredder\n\nThis guide outlines the construction of a bicycle-powered plastic shredder and provides instructions for building your own. The device offers a cost-effective method of shredding plastic without relying on electricity.\n\n**Step 1**: Find detailed construction plans and necessary files.\n\nVia this link: [drive.google.com](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing), you can access a detailed construction plan, bill of materials, technical drawings, and laser cutting files required to build a bicycle-powered shredder.\n\nNote: The files exceed the maximum allowed size for the supporting files tab.\n\nThe plans for constructing a shredder box are detailed. You can also purchase one.\n\nThis custom flywheel and axle generate momentum for shredding. It also serves as a base for connecting the gears discussed in step 5. Cutting files and technical drawings are available in the files in step 1.\n\nConstruct the shredder stand to provide an elevated platform for the shredded pieces to exit and to ensure safety. Our construction plan outlines potential optimizations based on issues we encountered.\n\nThe power output is amplified through two ratio transmissions totaling 1:4.6, resulting in 4.6 times more power at a reduced rotational speed. A large gear connects to the shredder box, and a substantial crankset is attached to the custom flywheel.\n\n### Shredding Process\n\nWith the final setup complete, begin shredding the plastic.",
"keywords": "bicycle-powered plastic shredder, DIY plastic shredder, build plastic shredder, construct bicycle shredder, cost-effective plastic shredding, manual plastic shredding, plastic shredder instructions, shredder construction plans, plastic recycling tools, non-electric shredder",
"resources": "### Software Requirements\n\n- Construction plans, bill of materials, and laser cutting files: [drive.google.com](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing)\n\n### Hardware Components\n\n- Shredder box (detailed construction plans)\n- Custom flywheel and axle (technical drawings included)\n- Shredder stand (optimized for safety and output)\n- Gear system (1:4.6 ratio transmission)\n- Large crankset (attached to flywheel)\n\n### Tools\n\n- Laser cutter (for fabricating components from cutting files)",
"references": "## Open-source Designs\n\n- [Bicycle-Powered Plastic Shredder Construction Files](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing)"
}

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---
title: Build a bicycle powered shredder!
slug: build-a-bicycle-powered-shredder
description: ### Tutorial: Constructing a Bicycle-Powered Plastic Shredder
This guide outlines the construction of a bicycle-powered plastic shredder and provides instructions for building your own. The device offers a cost-effective method of shredding plastic without relying on electricity.
**Step 1**: Find detailed construction plans and necessary files.
tags: ["collection","shredder","HDPE"]
category: uncategorized
difficulty: Hard
time: 3-4 weeks
location:
---
import { Image } from 'astro:assets'
# Build a bicycle powered shredder!
<Image src={import('./COVER_PHOTO.png')} alt="Build a bicycle powered shredder!" />
### Tutorial: Constructing a Bicycle-Powered Plastic Shredder
This guide outlines the construction of a bicycle-powered plastic shredder and provides instructions for building your own. The device offers a cost-effective method of shredding plastic without relying on electricity.
**Step 1**: Find detailed construction plans and necessary files.
## Steps
### Step 1: Open the construction manual
Via this link: [drive.google.com](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing), you can access a detailed construction plan, bill of materials, technical drawings, and laser cutting files required to build a bicycle-powered shredder.
Note: The files exceed the maximum allowed size for the supporting files tab.
<Image src={import('./CONSTRUCTION_MANUAL.png')} alt="CONSTRUCTION MANUAL.png" />
### Step 2: Built or buy the shredder box
The plans for constructing a shredder box are detailed. You can also purchase one.
<Image src={import('./Best-of-bike-shredder-15.jpg')} alt="Best-of-bike-shredder-15.jpg" />
### Step 3: Built the custom axle
This custom flywheel and axle generate momentum for shredding. It also serves as a base for connecting the gears discussed in step 5. Cutting files and technical drawings are available in the files in step 1.
<Image src={import('./Production-43.jpg')} alt="Production-43.jpg" />
<Image src={import('./Production-53.jpg')} alt="Production-53.jpg" />
### Step 4: Shredder stand and container
Construct the shredder stand to provide an elevated platform for the shredded pieces to exit and to ensure safety. Our construction plan outlines potential optimizations based on issues we encountered.
<Image src={import('./Production-23.jpg')} alt="Production-23.jpg" />
<Image src={import('./Production-44.jpg')} alt="Production-44.jpg" />
### Step 5: Attaching everything together
The power output is amplified through two ratio transmissions totaling 1:4.6, resulting in 4.6 times more power at a reduced rotational speed. A large gear connects to the shredder box, and a substantial crankset is attached to the custom flywheel.
<Image src={import('./transmission_2.png')} alt="transmission 2.png" />
<Image src={import('./transmission_1.png')} alt="transmission 1.png" />
### Step 6: Let's start shredding plastic!
### Shredding Process
With the final setup complete, begin shredding the plastic.
<Image src={import('./lets_start_shredding_plastic.png')} alt="let's start shredding plastic.png" />

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## Open-source Designs
- [Bicycle-Powered Plastic Shredder Construction Files](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing)

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### Software Requirements
- Construction plans, bill of materials, and laser cutting files: [drive.google.com](https://drive.google.com/drive/folders/1m8Bq35N_N-nw5llw7T16WAWR9GLb5i_L?usp=sharing)
### Hardware Components
- Shredder box (detailed construction plans)
- Custom flywheel and axle (technical drawings included)
- Shredder stand (optimized for safety and output)
- Gear system (1:4.6 ratio transmission)
- Large crankset (attached to flywheel)
### Tools
- Laser cutter (for fabricating components from cutting files)

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---
title: Build a Fishing Canoe
slug: build-a-fishing-canoe
description: At the Flipflopi Project, we initiated a unique boat-building course, utilizing waste plastic as the primary construction material. As a practical project, students constructed a local fishing dhow, "Dau la Mwao," a common vessel suitable for a short course.
This tutorial outlines the process and insights gained.
tags: ["product","HDPE"]
category: uncategorized
difficulty: Hard
time: 1+ months
keywords: Flipflopi Project, boat building course, waste plastic construction, fishing dhow Dau la Mwao, CAD mold design, HDPE materials, plastic extrusion, traditional canoe design, reinforcing brackets, plastic welding method
location: Lamu, Kenya
---
# Build a Fishing Canoe
![Build a Fishing Canoe](Screenshot_2023-03-09_at_14.58.35-186c63cfa30.png)
At the Flipflopi Project, we initiated a unique boat-building course, utilizing waste plastic as the primary construction material. As a practical project, students constructed a local fishing dhow, "Dau la Mwao," a common vessel suitable for a short course.
This tutorial outlines the process and insights gained.
User Location: Lamu, Kenya
## Steps
### Step 1: First things first
First, observe the entire process to gain an understanding.
Boatbuilding requires practice and experience, but with this video and the accompanying steps, you can potentially build your own.
### Step 2: Design Considerations
For this boat, we based our measurements on a traditional fishing canoe to create mould designs for fabrication. While alternative designs could be more efficient, we retained the traditional structure to align with existing boatbuilding methods and preserve heritage skills.
Our moulds are designed for multiple uses. For example, the L-shaped rib can double as a bracket for larger vessels, and the "Muli" mould is suitable for both the canoe and a larger Taxi dhow. This approach, however, results in heavier components.
![PXL_20230309_111109826-186c7a01d62.jpg](./PXL_20230309_111109826-186c7a01d62.jpg)
![Screenshot 2023-01-27 at 15.19.22-185f32b405b-186c7a0483e.png](./Screenshot_2023-01-27_at_15.19.22-185f32b405b-186c7a0483e.png)
### Step 3: Mould making
The custom molds were designed using CAD, and the accompanying drawings are available in the download files. These molds were plasma cut from 4 mm (0.16 inches) steel sheets. The mold sides featured alignment steps to ease assembly; however, due to the imprecision of the plasma cutter, significant manual finishing was required.
The remaining fabrication—assembling, bending, welding, drilling, and bolting—was completed internally. To prevent deformation under pressure, reinforcement brackets were installed on the sides.
Note: For future welding, we recommend cutting the metal parts with straight edges, omitting alignment steps, unless the cut quality is guaranteed. This approach simplifies the process and supports complete in-house fabrication, potentially reducing costs.
![Screenshot 2023-01-27 at 15.18.18-185f33dd541.png](./Screenshot_2023-01-27_at_15.18.18-185f33dd541.png)
![Screenshot 2023-01-27 at 15.38.55-185f33de7ff.png](./Screenshot_2023-01-27_at_15.38.55-185f33de7ff.png)
![Screenshot 2023-03-09 at 15.24.15-186c7a0cc34.png](./Screenshot_2023-03-09_at_15.24.15-186c7a0cc34.png)
### Step 4: Extruding
### Extrusion and Injection Process
For these parts, a high-speed, powerful extruder is necessary due to their large volume. We utilized an industrial extruder; however, an Extruder Pro might suffice (pending further testing).
Using our extruder, we filled the parts in 10-15 minutes with 15-20 kg (33-44 lbs) of plastic. To address shrinkage and air pockets, we continued injecting plastic for an additional 1-2 minutes after it appeared at the relief holes, ensuring better compression.
We exclusively used HDPE for our parts.
**Note:** Regularly inspect the quality of your parts. Variations in weight can indicate internal air pockets.
![20220902_152133-185f33d8b92.jpg](./20220902_152133-185f33d8b92.jpg)
### Step 5: Get ready for boat building!
### Materials and Tools for Boat Building
**Materials:**
- **Plastic Parts:** Custom components for L-ribs, V-rib, and front/back sections.
- **Lumber:** For base, hull, and interior, ideally at least 3 meters (9.8 feet) in length. Choose available strong materials.
**Fixings:** Screws, bolts, and corking cotton.
**Tools:**
- **Standard Tools:** Saws, chisels, drill, screwdrivers, ruler, square.
- **Specialty Tools:** Traditional dhow or boat-making tools.
- **Heat Equipment:** Heat gun or welding tool, melting machine.
**Space Requirements:** A flat area with a smooth floor facilitates easy collection of dust and particles.
![Tools-185f3ba6d1d.png](./Tools-185f3ba6d1d.png)
### Step 6: Utako and Levelling
### Keel Leveling Instructions
**Materials Required:**
- Keel Plank: 9x2 inches (22.86x5.08 cm), 16 feet (4.88 meters) long
- Base Logs: 5x5 inches (12.7x12.7 cm)
**Tools Needed:**
- Spirit Level
- Hose Pipe
**Procedure:**
1. Divide the keel into five equal segments and position a log at each division.
2. Position the keel plank, ensuring it is perfectly level.
3. Secure the keel to the base using nails or pegs on both sides.
4. Mark a center line on the keel to ensure proper alignment of subsequent components.
**Note:** Plastic planks may exhibit bending or twisting. Apply weight to correct and level them.
![IMG_4386-184c74fb28b.JPG](./IMG_4386-184c74fb28b.JPG)
### Step 7: Front and back Mulis
### Materials Needed
- Mulis (2 units)
- Temporary supporting poles (Mabunda)
### Process
1. **Mark Center Line:** Identify the front and back center lines on each Muli.
2. **Shape Muli:** If warped, trim the long sides of the Muli to straighten and balance.
3. **Cut Ribbet:** Tailor the ribbet according to the plank dimensions.
4. **Determine Angles:** Select angles for positioning Mulis on the keel (45° front, 70° back).
5. **Base Cutting:** Trim the Muli base to fit the selected angles.
6. **Mark and Chisel:** Outline the Mulis on the keel, then chisel to a depth of 1/2 inch (1.27 cm) and assemble.
7. **Support Mulis:** Stabilize with Mabundas affixed to sides and ends.
8. **Alignment Check:** Use a plumb bob (Kabiru) to ensure Mulis align straight with the center.
9. **Secure Position:** Drill through the Muli and keel; fasten with a nut and bolt.
**Note:** A silicone sealant was applied between surfaces, with cotton wrapped around the bolt for added sealing.
![IMG_4587-184c75c16d8.JPG](./IMG_4587-184c75c16d8.JPG)
![IMG_4691-184c75fe3e5.JPG](./IMG_4691-184c75fe3e5.JPG)
![IMG_4711-184c76012aa.JPG](./IMG_4711-184c76012aa.JPG)
### Step 8: Front and back Bitana
# Bitana Installation Guide
## Purpose
The Bitana serves as a bracket to secure the Muli to the Keel.
## Materials
- Two L-shaped rib pieces
## Instructions
1. Shape each rib piece to align with the angle between the Muli and the keel.
2. Taper the ribs to accommodate adjacent planks.
3. Drill and bolt the ribs to both the Muli and the Keel.
Repeat this process for both the front and back sides.
![IMG_4850-184c765f5fa.JPG](./IMG_4850-184c765f5fa.JPG)
### Step 9: Define the boat shape
Certainly.
---
You can select varying widths based on the intended use of the boat. For comfortably transporting people, we decided on a width one-quarter of the length. It's useful to align the width with the available planks.
### Materials
- "Mapande" (wooden poles)
- A flexible, thin piece of wood or plastic for temporary "kinara" (top plank of the hull)
### Process
1. Attach Mapande at the boat's widest point.
2. Shape the boat with thin planks.
3. Use a rope or ruler/tape measure to ensure equal width on both sides.
4. Position the remaining Mapande on the base beams.
5. Fix the temporary "kinara" on the Mapande to maintain shape.
6. Use "Mitindikani" (horizontal poles) to secure the position.
---
![IMG_4782-184c76f30be.JPG](./IMG_4782-184c76f30be.JPG)
![IMG_4648-184c76f6f7c.JPG](./IMG_4648-184c76f6f7c.JPG)
### Step 10: Mataruma (Ribs)
## Materials:
- L-shape ribs (14x)
## Process:
1. Arrange ribs in pairs with 30.5 cm (12 inches) between pairs.
2. Ensure weight distribution is balanced front/back and left/right.
3. Cut longer pieces to match the shape.
4. Use a square to align ribs at a right angle to the keel.
5. If pieces are warped, use a planer or saw for correction.
6. Bolt ribs to the keel.
7. Add cross poles to secure ribs.
![IMG_4929-184c77bfc3a.JPG](./IMG_4929-184c77bfc3a.JPG)
![IMG_4888-184c77c494c.JPG](./IMG_4888-184c77c494c.JPG)
### Step 11: Farkumu
Materials
- V-shape ribs "Farkumu" (2x)
Instructions:
- Position the V-shape beam on the Bitana and create a lap joint to connect them.
- Secure with a bolt through the keel.
![IMG_4858-184c79b9ddd.JPG](./IMG_4858-184c79b9ddd.JPG)
![IMG_4842-184c79e2260.JPG](./IMG_4842-184c79e2260.JPG)
### Step 12: Kinara (top hull)
### Fitting the Hull
**Materials:** 9x1.5" (22.86x3.81 cm) planks, 10 pieces
**Instructions:**
1. **Prepare the Top Plank (Kinara):**
- Mark and cut the bevel according to specifications.
- Position and secure the plank using clamps.
- Adjust ribs as needed for proper alignment.
- Fasten the plank with screws.
2. **Attach Additional Planks:**
- Repeat the fitting process for the second piece.
- Cut a Z-joint to connect the pieces securely.
3. **Complete the Top Perimeter:**
- Ensure the Kinara encircles the top on both sides.
![IMG_4946-184c7ab3e31.JPG](./IMG_4946-184c7ab3e31.JPG)
![IMG_4998-184c7ab8784.JPG](./IMG_4998-184c7ab8784.JPG)
![IMG_5044-184c7ac6916.JPG](./IMG_5044-184c7ac6916.JPG)
### Step 13: Wajihi (rest of hull)
Materials: 9x1.5" planks (6 pcs)
- Complete the remaining rows with the same method.
- Unlike the top plank, a bevel joint may be used between the planks instead of a Z-joint.
- Alternate joint positions to prevent weak points where joints align.
Ensure all planks fit tightly with minimal gaps. Use a saw to trim uneven edges if necessary.
![Screenshot 2023-01-28 at 20.56.36-185f986f8da.png](./Screenshot_2023-01-28_at_20.56.36-185f986f8da.png)
### Step 14: Top locking
### Materials
- Tampisi: 2x3 inches (5.1x7.6 cm) planks (4 pieces)
- Fundo la mongoti (crossing beam for the mast): 9x2 inches (22.9x5.1 cm)
- Fundo la nyuma (back crossing beam): 9x1.5 inches (22.9x3.8 cm)
### Process
1. Cut a step into the ribs to ensure the tampisi and firari fit flush against the sides.
2. Place the tampisi onto the step and secure it with screws.
3. Position "fundo la mongoti" atop the tampisi at one-third of the keel from the front.
4. Position "fundo la nyuma" atop the tampisi at the desired location in the back.
5. Create lap joints between the Tampisi and Fundos, securing with bolts.
![IMG_5165-184c7b2d9ea.JPG](./IMG_5165-184c7b2d9ea.JPG)
![IMG_5178-184c7b36459.JPG](./IMG_5178-184c7b36459.JPG)
### Step 15: Staha
Staha is designed to reinforce the Muli to Kinara, providing both seating and storage.
Materials Required:
- 9x1.5" (22.9x3.8 cm) plank
- 2x4" (5.1x10.2 cm) plank
Process:
FRONT STAHA
- Trim the top of the muli to align with the top plank.
- Position a 2x4" (5.1x10.2 cm) beam perpendicularly to the center line for support.
- Cut planks to fit over the boat's front triangle.
BACK STAHA
- Fit two planks to create a seating base, leaving an opening for rope attachment.
![IMG_5175-184c7b7963b.JPG](./IMG_5175-184c7b7963b.JPG)
![IMG_5248-184c7b7c2c7.JPG](./IMG_5248-184c7b7c2c7.JPG)
### Step 16: Firari + Dufani
Firari and Dufani reinforce the top edges and structure.
Materials:
- Dufani (5x1", 4 pieces)
- Firari (2.5x1", 4 pieces)
Firari Process:
1. Position Firari at the top of the structure and shave them to level with Dufani.
2. Ensure the distance between Firari and adjacent parts is parallel.
3. Join the planks with a bevel joint and secure with screws.
Dufani Process:
1. Cut the front angle for a proper fit at the corners.
2. Bend the plank gradually: clamp the first foot (approx. 12"), screw in place, then continue bending and securing every foot until fully bent.
3. Repeat the process from the opposite end, meeting in the center with a bevel joint.
![IMG_5396-184c7ba18a8.JPG](./IMG_5396-184c7ba18a8.JPG)
![IMG_5405-184c7c1b10f.JPG](./IMG_5405-184c7c1b10f.JPG)
### Step 17: Finish the base
Flip the dhow to complete the base.
Ensure you create a water channel on both sides.
Cut the planks to match the base's shape, minimizing gaps.
Secure them to the ribs. Base complete.
![IMG_5452-184c7c449b7.JPG](./IMG_5452-184c7c449b7.JPG)
![IMG_5485-184c7c81a7f.JPG](./IMG_5485-184c7c81a7f.JPG)
![IMG_5544-184c7c85881.JPG](./IMG_5544-184c7c85881.JPG)
### Step 18: Finishing & Sealing
### Finalizing and Sealing the Dhow
1. Trim the excess corners of the planks to smooth the hull's surface.
2. Use traditional caulking with cotton, inserting it between plank gaps with a "chembeo."
3. Complete the process by sealing with melted plastic using a heat gun, a method akin to plastic welding.
4. Apply plastic welding to seal screws and other gaps.
**Note:** The plastic welding used was rudimentary and requires further testing. Results from using a specialized plastic welding tool will be shared in the future.
![IMG_5518-184c7d11c82.JPG](./IMG_5518-184c7d11c82.JPG)
![IMG_5724-184c7d14b69.JPG](./IMG_5724-184c7d14b69.JPG)
![IMG_5636-184c7d199c5.JPG](./IMG_5636-184c7d199c5.JPG)
### Step 19: Testing & finalising hull
After completing the hull and initial sealing, it's time for testing:
- Invert the boat
- Launch into water or fill it
- Identify any leaks by observing water entry points
- Complete sealing at those locations
![IMG_5768-184c7d32d31.JPG](./IMG_5768-184c7d32d31.JPG)
### Step 20: Rigging / Powering
Congratulations, you have completed the initial steps.
Now choose your boat's propulsion method: motor, paddles, or sail.
Our preference is a sail with a rudder. We used traditional wooden mast and boom. A visually striking sail can also serve as an attention-grabber.
![Dau la Mwao-184c7d73126.jpg](./Dau_la_Mwao-184c7d73126.jpg)
![IMG_5985-185f98fb7a0.JPG](./IMG_5985-185f98fb7a0.JPG)
![IMG_5947-185f99050df.JPG](./IMG_5947-185f99050df.JPG)
### Step 21: SAIL AND INSPIRE
# Tutorial Conclusion
Encourage others and share your experience. If you pursue a similar project or find inspiration in this, please inform us. We welcome your feedback.
Always keep a tool handy to remove water. Even if it's not entering from below, it may be entering with the waves.
![IMG_6324-185f91722da.JPG](./IMG_6324-185f91722da.JPG)
## Resources
### Materials
- HDPE plastic (exclusively used for molded parts)
- Lumber (minimum 3 meters length for structural components)
- Steel sheets (4 mm thickness for custom molds)
- Screws, bolts, and corking cotton (for fastening and sealing)
- Custom plastic components (L-ribs, V-rib, front/back sections)
### Tools
- Saws, chisels, drill, and screwdrivers (basic construction)
- Heat gun or welding tool (plastic shaping/sealing) ~~[Example](https://example.com/heat-tools)~~
- Spirit level and hose pipe (keel alignment)
- Plumb bob ("Kabiru" for vertical alignment checks)
- Traditional dhow boat-making tools (heritage craftsmanship)
### Software
- CAD software (for mold design and precision-cutting plans) ~~[Example](https://example.com/cad-software)~~
### Hardware
- Industrial extruder (high-speed plastic injection) ~~[Example](https://example.com/extruders)~~
- Plasma cutter (4 mm steel mold fabrication) ~~[Example](https://example.com/plasma-cutters)~~
- Melting machine (plastic processing)
- Reinforced steel molds (reusable for multiple projects)
- Power drill (assembly and fastening)
### Safety/Other
- Silicone sealant (waterproofing joints)
- Protective gloves (handling hot materials) ~~[Example](https://example.com/safety-gear)~~
- Rope/tape measure (symmetry checks during shaping)
- Temporary support poles ("Mabunda" for stabilizing Mulis)
- Plastic welding kit (advanced sealing; pending future tests) ~~[Example](https://example.com/welding-kits)~~
## References
### Articles
- [The Flipflopi Project: Mitigating Plastic Pollution through Heritage Boat Building](https://smepprogramme.org/project/the-flipflopi-project/)
- [Making A Recycled Plastic Boat](https://atomicshrimp.com/post/2011/07/31/Making-A-Recycled-Plastic-Boat)
- [Shipbuilding Fabrications, CNC Plasma Cutter - Beamcut](https://beamcut.com/robotic-plasma-cutting-technology-marine-structural-steel-fabrication/)
- [Traditional Dhow Building In Ras Al Khaimah](https://visitrasalkhaimah.com/blog/traditional-dhow-building-in-ras-al-khaimah/)
- [Solar-electric taxi boat sets sail in Kenya](https://www.ncl.ac.uk/press/articles/latest/2024/04/flipflopiproject/)
- [Closing the Loop on Waste Plastics Through Heritage Boat Building](https://www.unesco.org/en/articles/closing-loop-waste-plastics-through-heritage-boat-building)
- [The boat that will try tackling the global plastic pollution-flipflopi](https://timesofindia.indiatimes.com/blogs/scientifically-trended/the-boat-that-will-try-tackling-the-global-plastic-pollution-flipflopi/)
- [Kenyan Taxi Boat From Recycled Plastic Waste Ready to Ride](https://newscentral.africa/kenyan-taxi-boat-from-recycled-plastic-waste-ready-to-ride/)
### Books
- [Flipflopi: How a Boat Made from Flip-Flops Is Helping to Save the Ocean](https://www.sincerelystacie.com/2023/04/childrens-book-review-flipflopi-by-linda-ravin-lodding-and-dipesh-pabari/)
- [Flipflopi, how a boat made from flip-flops is helping to save the ocean](https://africaaccessreview.org/2023/11/flipflopi-how-a-boat-made-from-flip-flops-is-helping-to-save-the-ocean/)
- [Today's read... FlipFlopi by Linda Ravin Lodding and Dipesh Pabari](https://www.bookwormforkids.com/2023/03/todays-read-flipflopi-by-linda-ravin.html)
### YouTube
- [The Flipflopi Expedition: An Overview](https://www.youtube.com/watch?v=JcBajK5gjC0)
- [Renovating our first recycled plastic sailing boat](https://www.youtube.com/watch?v=scBeQNzvsGQ)
### Opensource Designs
- [The Plastic Bin Boat : 10 Steps](https://www.instructables.com/The-Plastic-Bin-Boat/)
- [Boatbuilding Toolkit - The Flipflopi](https://www.theflipflopi.com/boatbuilding-toolkit)
- [Launching the Boat Build Toolkit](https://www.theflipflopi.com/blog/launching-the-boat-build-toolkit)

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---
title: Build a Fishing Canoe
slug: build-a-fishing-canoe
description: At the Flipflopi Project, we initiated a unique boat-building course, utilizing waste plastic as the primary construction material. As a practical project, students constructed a local fishing dhow, "Dau la Mwao," a common vessel suitable for a short course.
This tutorial outlines the process and insights gained.
tags: ["product","HDPE"]
category: uncategorized
difficulty: Hard
time: 1+ months
location: Lamu, Kenya
---
import { Image } from 'astro:assets'
# Build a Fishing Canoe
<Image src={import('./Screenshot_2023-03-09_at_14.58.35-186c63cfa30.png')} alt="Build a Fishing Canoe" />
At the Flipflopi Project, we initiated a unique boat-building course, utilizing waste plastic as the primary construction material. As a practical project, students constructed a local fishing dhow, "Dau la Mwao," a common vessel suitable for a short course.
This tutorial outlines the process and insights gained.
User Location: Lamu, Kenya
## Steps
### Step 1: First things first
First, observe the entire process to gain an understanding.
Boatbuilding requires practice and experience, but with this video and the accompanying steps, you can potentially build your own.
### Step 2: Design Considerations
For this boat, we based our measurements on a traditional fishing canoe to create mould designs for fabrication. While alternative designs could be more efficient, we retained the traditional structure to align with existing boatbuilding methods and preserve heritage skills.
Our moulds are designed for multiple uses. For example, the L-shaped rib can double as a bracket for larger vessels, and the "Muli" mould is suitable for both the canoe and a larger Taxi dhow. This approach, however, results in heavier components.
<Image src={import('./PXL_20230309_111109826-186c7a01d62.jpg')} alt="PXL_20230309_111109826-186c7a01d62.jpg" />
<Image src={import('./Screenshot_2023-01-27_at_15.19.22-185f32b405b-186c7a0483e.png')} alt="Screenshot 2023-01-27 at 15.19.22-185f32b405b-186c7a0483e.png" />
### Step 3: Mould making
The custom molds were designed using CAD, and the accompanying drawings are available in the download files. These molds were plasma cut from 4 mm (0.16 inches) steel sheets. The mold sides featured alignment steps to ease assembly; however, due to the imprecision of the plasma cutter, significant manual finishing was required.
The remaining fabrication—assembling, bending, welding, drilling, and bolting—was completed internally. To prevent deformation under pressure, reinforcement brackets were installed on the sides.
Note: For future welding, we recommend cutting the metal parts with straight edges, omitting alignment steps, unless the cut quality is guaranteed. This approach simplifies the process and supports complete in-house fabrication, potentially reducing costs.
<Image src={import('./Screenshot_2023-01-27_at_15.18.18-185f33dd541.png')} alt="Screenshot 2023-01-27 at 15.18.18-185f33dd541.png" />
<Image src={import('./Screenshot_2023-01-27_at_15.38.55-185f33de7ff.png')} alt="Screenshot 2023-01-27 at 15.38.55-185f33de7ff.png" />
<Image src={import('./Screenshot_2023-03-09_at_15.24.15-186c7a0cc34.png')} alt="Screenshot 2023-03-09 at 15.24.15-186c7a0cc34.png" />
### Step 4: Extruding
### Extrusion and Injection Process
For these parts, a high-speed, powerful extruder is necessary due to their large volume. We utilized an industrial extruder; however, an Extruder Pro might suffice (pending further testing).
Using our extruder, we filled the parts in 10-15 minutes with 15-20 kg (33-44 lbs) of plastic. To address shrinkage and air pockets, we continued injecting plastic for an additional 1-2 minutes after it appeared at the relief holes, ensuring better compression.
We exclusively used HDPE for our parts.
**Note:** Regularly inspect the quality of your parts. Variations in weight can indicate internal air pockets.
<Image src={import('./20220902_152133-185f33d8b92.jpg')} alt="20220902_152133-185f33d8b92.jpg" />
### Step 5: Get ready for boat building!
### Materials and Tools for Boat Building
**Materials:**
- **Plastic Parts:** Custom components for L-ribs, V-rib, and front/back sections.
- **Lumber:** For base, hull, and interior, ideally at least 3 meters (9.8 feet) in length. Choose available strong materials.
**Fixings:** Screws, bolts, and corking cotton.
**Tools:**
- **Standard Tools:** Saws, chisels, drill, screwdrivers, ruler, square.
- **Specialty Tools:** Traditional dhow or boat-making tools.
- **Heat Equipment:** Heat gun or welding tool, melting machine.
**Space Requirements:** A flat area with a smooth floor facilitates easy collection of dust and particles.
<Image src={import('./Tools-185f3ba6d1d.png')} alt="Tools-185f3ba6d1d.png" />
### Step 6: Utako and Levelling
### Keel Leveling Instructions
**Materials Required:**
- Keel Plank: 9x2 inches (22.86x5.08 cm), 16 feet (4.88 meters) long
- Base Logs: 5x5 inches (12.7x12.7 cm)
**Tools Needed:**
- Spirit Level
- Hose Pipe
**Procedure:**
1. Divide the keel into five equal segments and position a log at each division.
2. Position the keel plank, ensuring it is perfectly level.
3. Secure the keel to the base using nails or pegs on both sides.
4. Mark a center line on the keel to ensure proper alignment of subsequent components.
**Note:** Plastic planks may exhibit bending or twisting. Apply weight to correct and level them.
<Image src={import('./IMG_4386-184c74fb28b.JPG')} alt="IMG_4386-184c74fb28b.JPG" />
### Step 7: Front and back Mulis
### Materials Needed
- Mulis (2 units)
- Temporary supporting poles (Mabunda)
### Process
1. **Mark Center Line:** Identify the front and back center lines on each Muli.
2. **Shape Muli:** If warped, trim the long sides of the Muli to straighten and balance.
3. **Cut Ribbet:** Tailor the ribbet according to the plank dimensions.
4. **Determine Angles:** Select angles for positioning Mulis on the keel (45° front, 70° back).
5. **Base Cutting:** Trim the Muli base to fit the selected angles.
6. **Mark and Chisel:** Outline the Mulis on the keel, then chisel to a depth of 1/2 inch (1.27 cm) and assemble.
7. **Support Mulis:** Stabilize with Mabundas affixed to sides and ends.
8. **Alignment Check:** Use a plumb bob (Kabiru) to ensure Mulis align straight with the center.
9. **Secure Position:** Drill through the Muli and keel; fasten with a nut and bolt.
**Note:** A silicone sealant was applied between surfaces, with cotton wrapped around the bolt for added sealing.
<Image src={import('./IMG_4587-184c75c16d8.JPG')} alt="IMG_4587-184c75c16d8.JPG" />
<Image src={import('./IMG_4691-184c75fe3e5.JPG')} alt="IMG_4691-184c75fe3e5.JPG" />
<Image src={import('./IMG_4711-184c76012aa.JPG')} alt="IMG_4711-184c76012aa.JPG" />
### Step 8: Front and back Bitana
# Bitana Installation Guide
## Purpose
The Bitana serves as a bracket to secure the Muli to the Keel.
## Materials
- Two L-shaped rib pieces
## Instructions
1. Shape each rib piece to align with the angle between the Muli and the keel.
2. Taper the ribs to accommodate adjacent planks.
3. Drill and bolt the ribs to both the Muli and the Keel.
Repeat this process for both the front and back sides.
<Image src={import('./IMG_4850-184c765f5fa.JPG')} alt="IMG_4850-184c765f5fa.JPG" />
### Step 9: Define the boat shape
Certainly.
---
You can select varying widths based on the intended use of the boat. For comfortably transporting people, we decided on a width one-quarter of the length. It's useful to align the width with the available planks.
### Materials
- "Mapande" (wooden poles)
- A flexible, thin piece of wood or plastic for temporary "kinara" (top plank of the hull)
### Process
1. Attach Mapande at the boat's widest point.
2. Shape the boat with thin planks.
3. Use a rope or ruler/tape measure to ensure equal width on both sides.
4. Position the remaining Mapande on the base beams.
5. Fix the temporary "kinara" on the Mapande to maintain shape.
6. Use "Mitindikani" (horizontal poles) to secure the position.
---
<Image src={import('./IMG_4782-184c76f30be.JPG')} alt="IMG_4782-184c76f30be.JPG" />
<Image src={import('./IMG_4648-184c76f6f7c.JPG')} alt="IMG_4648-184c76f6f7c.JPG" />
### Step 10: Mataruma (Ribs)
## Materials:
- L-shape ribs (14x)
## Process:
1. Arrange ribs in pairs with 30.5 cm (12 inches) between pairs.
2. Ensure weight distribution is balanced front/back and left/right.
3. Cut longer pieces to match the shape.
4. Use a square to align ribs at a right angle to the keel.
5. If pieces are warped, use a planer or saw for correction.
6. Bolt ribs to the keel.
7. Add cross poles to secure ribs.
<Image src={import('./IMG_4929-184c77bfc3a.JPG')} alt="IMG_4929-184c77bfc3a.JPG" />
<Image src={import('./IMG_4888-184c77c494c.JPG')} alt="IMG_4888-184c77c494c.JPG" />
### Step 11: Farkumu
Materials
- V-shape ribs "Farkumu" (2x)
Instructions:
- Position the V-shape beam on the Bitana and create a lap joint to connect them.
- Secure with a bolt through the keel.
<Image src={import('./IMG_4858-184c79b9ddd.JPG')} alt="IMG_4858-184c79b9ddd.JPG" />
<Image src={import('./IMG_4842-184c79e2260.JPG')} alt="IMG_4842-184c79e2260.JPG" />
### Step 12: Kinara (top hull)
### Fitting the Hull
**Materials:** 9x1.5" (22.86x3.81 cm) planks, 10 pieces
**Instructions:**
1. **Prepare the Top Plank (Kinara):**
- Mark and cut the bevel according to specifications.
- Position and secure the plank using clamps.
- Adjust ribs as needed for proper alignment.
- Fasten the plank with screws.
2. **Attach Additional Planks:**
- Repeat the fitting process for the second piece.
- Cut a Z-joint to connect the pieces securely.
3. **Complete the Top Perimeter:**
- Ensure the Kinara encircles the top on both sides.
<Image src={import('./IMG_4946-184c7ab3e31.JPG')} alt="IMG_4946-184c7ab3e31.JPG" />
<Image src={import('./IMG_4998-184c7ab8784.JPG')} alt="IMG_4998-184c7ab8784.JPG" />
<Image src={import('./IMG_5044-184c7ac6916.JPG')} alt="IMG_5044-184c7ac6916.JPG" />
### Step 13: Wajihi (rest of hull)
Materials: 9x1.5" planks (6 pcs)
- Complete the remaining rows with the same method.
- Unlike the top plank, a bevel joint may be used between the planks instead of a Z-joint.
- Alternate joint positions to prevent weak points where joints align.
Ensure all planks fit tightly with minimal gaps. Use a saw to trim uneven edges if necessary.
<Image src={import('./Screenshot_2023-01-28_at_20.56.36-185f986f8da.png')} alt="Screenshot 2023-01-28 at 20.56.36-185f986f8da.png" />
### Step 14: Top locking
### Materials
- Tampisi: 2x3 inches (5.1x7.6 cm) planks (4 pieces)
- Fundo la mongoti (crossing beam for the mast): 9x2 inches (22.9x5.1 cm)
- Fundo la nyuma (back crossing beam): 9x1.5 inches (22.9x3.8 cm)
### Process
1. Cut a step into the ribs to ensure the tampisi and firari fit flush against the sides.
2. Place the tampisi onto the step and secure it with screws.
3. Position "fundo la mongoti" atop the tampisi at one-third of the keel from the front.
4. Position "fundo la nyuma" atop the tampisi at the desired location in the back.
5. Create lap joints between the Tampisi and Fundos, securing with bolts.
<Image src={import('./IMG_5165-184c7b2d9ea.JPG')} alt="IMG_5165-184c7b2d9ea.JPG" />
<Image src={import('./IMG_5178-184c7b36459.JPG')} alt="IMG_5178-184c7b36459.JPG" />
### Step 15: Staha
Staha is designed to reinforce the Muli to Kinara, providing both seating and storage.
Materials Required:
- 9x1.5" (22.9x3.8 cm) plank
- 2x4" (5.1x10.2 cm) plank
Process:
FRONT STAHA
- Trim the top of the muli to align with the top plank.
- Position a 2x4" (5.1x10.2 cm) beam perpendicularly to the center line for support.
- Cut planks to fit over the boat's front triangle.
BACK STAHA
- Fit two planks to create a seating base, leaving an opening for rope attachment.
<Image src={import('./IMG_5175-184c7b7963b.JPG')} alt="IMG_5175-184c7b7963b.JPG" />
<Image src={import('./IMG_5248-184c7b7c2c7.JPG')} alt="IMG_5248-184c7b7c2c7.JPG" />
### Step 16: Firari + Dufani
Firari and Dufani reinforce the top edges and structure.
Materials:
- Dufani (5x1", 4 pieces)
- Firari (2.5x1", 4 pieces)
Firari Process:
1. Position Firari at the top of the structure and shave them to level with Dufani.
2. Ensure the distance between Firari and adjacent parts is parallel.
3. Join the planks with a bevel joint and secure with screws.
Dufani Process:
1. Cut the front angle for a proper fit at the corners.
2. Bend the plank gradually: clamp the first foot (approx. 12"), screw in place, then continue bending and securing every foot until fully bent.
3. Repeat the process from the opposite end, meeting in the center with a bevel joint.
<Image src={import('./IMG_5396-184c7ba18a8.JPG')} alt="IMG_5396-184c7ba18a8.JPG" />
<Image src={import('./IMG_5405-184c7c1b10f.JPG')} alt="IMG_5405-184c7c1b10f.JPG" />
### Step 17: Finish the base
Flip the dhow to complete the base.
Ensure you create a water channel on both sides.
Cut the planks to match the base's shape, minimizing gaps.
Secure them to the ribs. Base complete.
<Image src={import('./IMG_5452-184c7c449b7.JPG')} alt="IMG_5452-184c7c449b7.JPG" />
<Image src={import('./IMG_5485-184c7c81a7f.JPG')} alt="IMG_5485-184c7c81a7f.JPG" />
<Image src={import('./IMG_5544-184c7c85881.JPG')} alt="IMG_5544-184c7c85881.JPG" />
### Step 18: Finishing & Sealing
### Finalizing and Sealing the Dhow
1. Trim the excess corners of the planks to smooth the hull's surface.
2. Use traditional caulking with cotton, inserting it between plank gaps with a "chembeo."
3. Complete the process by sealing with melted plastic using a heat gun, a method akin to plastic welding.
4. Apply plastic welding to seal screws and other gaps.
**Note:** The plastic welding used was rudimentary and requires further testing. Results from using a specialized plastic welding tool will be shared in the future.
<Image src={import('./IMG_5518-184c7d11c82.JPG')} alt="IMG_5518-184c7d11c82.JPG" />
<Image src={import('./IMG_5724-184c7d14b69.JPG')} alt="IMG_5724-184c7d14b69.JPG" />
<Image src={import('./IMG_5636-184c7d199c5.JPG')} alt="IMG_5636-184c7d199c5.JPG" />
### Step 19: Testing & finalising hull
After completing the hull and initial sealing, it's time for testing:
- Invert the boat
- Launch into water or fill it
- Identify any leaks by observing water entry points
- Complete sealing at those locations
<Image src={import('./IMG_5768-184c7d32d31.JPG')} alt="IMG_5768-184c7d32d31.JPG" />
### Step 20: Rigging / Powering
Congratulations, you have completed the initial steps.
Now choose your boat's propulsion method: motor, paddles, or sail.
Our preference is a sail with a rudder. We used traditional wooden mast and boom. A visually striking sail can also serve as an attention-grabber.
<Image src={import('./Dau_la_Mwao-184c7d73126.jpg')} alt="Dau la Mwao-184c7d73126.jpg" />
<Image src={import('./IMG_5985-185f98fb7a0.JPG')} alt="IMG_5985-185f98fb7a0.JPG" />
<Image src={import('./IMG_5947-185f99050df.JPG')} alt="IMG_5947-185f99050df.JPG" />
### Step 21: SAIL AND INSPIRE
# Tutorial Conclusion
Encourage others and share your experience. If you pursue a similar project or find inspiration in this, please inform us. We welcome your feedback.
Always keep a tool handy to remove water. Even if it's not entering from below, it may be entering with the waves.
<Image src={import('./IMG_6324-185f91722da.JPG')} alt="IMG_6324-185f91722da.JPG" />

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### Articles
- [The Flipflopi Project: Mitigating Plastic Pollution through Heritage Boat Building](https://smepprogramme.org/project/the-flipflopi-project/)
- [Making A Recycled Plastic Boat](https://atomicshrimp.com/post/2011/07/31/Making-A-Recycled-Plastic-Boat)
- [Shipbuilding Fabrications, CNC Plasma Cutter - Beamcut](https://beamcut.com/robotic-plasma-cutting-technology-marine-structural-steel-fabrication/)
- [Traditional Dhow Building In Ras Al Khaimah](https://visitrasalkhaimah.com/blog/traditional-dhow-building-in-ras-al-khaimah/)
- [Solar-electric taxi boat sets sail in Kenya](https://www.ncl.ac.uk/press/articles/latest/2024/04/flipflopiproject/)
- [Closing the Loop on Waste Plastics Through Heritage Boat Building](https://www.unesco.org/en/articles/closing-loop-waste-plastics-through-heritage-boat-building)
- [The boat that will try tackling the global plastic pollution-flipflopi](https://timesofindia.indiatimes.com/blogs/scientifically-trended/the-boat-that-will-try-tackling-the-global-plastic-pollution-flipflopi/)
- [Kenyan Taxi Boat From Recycled Plastic Waste Ready to Ride](https://newscentral.africa/kenyan-taxi-boat-from-recycled-plastic-waste-ready-to-ride/)
### Books
- [Flipflopi: How a Boat Made from Flip-Flops Is Helping to Save the Ocean](https://www.sincerelystacie.com/2023/04/childrens-book-review-flipflopi-by-linda-ravin-lodding-and-dipesh-pabari/)
- [Flipflopi, how a boat made from flip-flops is helping to save the ocean](https://africaaccessreview.org/2023/11/flipflopi-how-a-boat-made-from-flip-flops-is-helping-to-save-the-ocean/)
- [Today's read... FlipFlopi by Linda Ravin Lodding and Dipesh Pabari](https://www.bookwormforkids.com/2023/03/todays-read-flipflopi-by-linda-ravin.html)
### YouTube
- [The Flipflopi Expedition: An Overview](https://www.youtube.com/watch?v=JcBajK5gjC0)
- [Renovating our first recycled plastic sailing boat](https://www.youtube.com/watch?v=scBeQNzvsGQ)
### Opensource Designs
- [The Plastic Bin Boat : 10 Steps](https://www.instructables.com/The-Plastic-Bin-Boat/)
- [Boatbuilding Toolkit - The Flipflopi](https://www.theflipflopi.com/boatbuilding-toolkit)
- [Launching the Boat Build Toolkit](https://www.theflipflopi.com/blog/launching-the-boat-build-toolkit)

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### Materials
- HDPE plastic (exclusively used for molded parts)
- Lumber (minimum 3 meters length for structural components)
- Steel sheets (4 mm thickness for custom molds)
- Screws, bolts, and corking cotton (for fastening and sealing)
- Custom plastic components (L-ribs, V-rib, front/back sections)
### Tools
- Saws, chisels, drill, and screwdrivers (basic construction)
- Heat gun or welding tool (plastic shaping/sealing) ~~[Example](https://example.com/heat-tools)~~
- Spirit level and hose pipe (keel alignment)
- Plumb bob ("Kabiru" for vertical alignment checks)
- Traditional dhow boat-making tools (heritage craftsmanship)
### Software
- CAD software (for mold design and precision-cutting plans) ~~[Example](https://example.com/cad-software)~~
### Hardware
- Industrial extruder (high-speed plastic injection) ~~[Example](https://example.com/extruders)~~
- Plasma cutter (4 mm steel mold fabrication) ~~[Example](https://example.com/plasma-cutters)~~
- Melting machine (plastic processing)
- Reinforced steel molds (reusable for multiple projects)
- Power drill (assembly and fastening)
### Safety/Other
- Silicone sealant (waterproofing joints)
- Protective gloves (handling hot materials) ~~[Example](https://example.com/safety-gear)~~
- Rope/tape measure (symmetry checks during shaping)
- Temporary support poles ("Mabunda" for stabilizing Mulis)
- Plastic welding kit (advanced sealing; pending future tests) ~~[Example](https://example.com/welding-kits)~~

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---
title: Build easy-to-wash chicken coop from bottle caps
slug: build-easy-to-wash-chicken-coop-from-bottle-caps
description: Recycled plastic sheets are ideal for chicken coops due to their ease of cleaning and resistance to parasites like poultry red mites. Here is how ours was built: Download the plans and watch the stages in the accompanying video.
tags: ["product","HDPE","sheetpress"]
category: Products
difficulty: Hard
time: 3-4 weeks
keywords: recycled plastic chicken coop, easy cleaning poultry coop, parasite resistant coop, chicken coop building plans, plastic sheet henhouse, bottle cap plastic recycling, DIY poultry housing, eco-friendly chicken coop, Trespa panels chicken coop, insulated chicken coop roof
location: Houyet, Belgium
---
# Build easy-to-wash chicken coop from bottle caps
![Build easy-to-wash chicken coop from bottle caps](20230522_140027-18b00b8c426.jpg)
Recycled plastic sheets are ideal for chicken coops due to their ease of cleaning and resistance to parasites like poultry red mites. Here is how ours was built: Download the plans and watch the stages in the accompanying video.
User Location: Houyet, Belgium
## Steps
### Step 1: Watch that amazing Youtube video first !
In this video, I demonstrate the production stages of a chicken coop made from plastic sheets. Watching the video will provide a comprehensive overview, making the process easier to follow.
### Step 2: Download the files provided above
The files contain henhouse plans in .PDF and .DXF formats for viewing and modification with open-source software like LibreCAD. The wooden structure is designed for panels measuring 39*39*0.4 inches (100*100*1 cm).
![librecad-18b242fed04.jpg](./librecad-18b242fed04.jpg)
### Step 3: Collect around 120 000 bottle caps
Collecting a substantial number of caps can be challenging. Here is my approach:
I collaborate with an organization that gathers caps from schools, stores, and public places and sorts them by color. I pay for this service to save time.
Seek out similar organizations in your area. Often, these groups collect bottle caps and sell them, using the proceeds to support charitable activities such as providing guide dogs for the blind or wheelchairs for the disabled.
For this project, we required 240 kilograms (approximately 530 pounds) of bottle caps.
![souffleunpeu2-18b1eafc264.jpg](./souffleunpeu2-18b1eafc264.jpg)
![bscap0029-18b1ebf50dc.jpg](./bscap0029-18b1ebf50dc.jpg)
### Step 4: Shred & wash your bottle caps
### Shredding
I use a V4 pro shredder to process the caps four times until the shred meets my size requirements.
### Washing and Drying
Washing is more effective post-grinding. I place shredded plastic in durable cotton canvas bags, securing them with reusable zip-ties. These are washed in domestic machines equipped with filtration systems to prevent microplastic release and water recovery systems to recycle water efficiently.
Subsequently, I dry the shredded material in tumble dryers to ensure it is completely dry.
![20220912_130432 (3)-18b1eb620eb.jpg](./20220912_130432_3-18b1eb620eb.jpg)
![20220912_130442 (1)-18b1eb63475.jpg](./20220912_130442_1-18b1eb63475.jpg)
![bscap0026-18b1eba04f6.jpg](./bscap0026-18b1eba04f6.jpg)
### Step 5: Create your sheets using the sheetpress
By following the previously explained method, you can produce approximately 6 to 8 sheets per day (2.5 to 3.5 square feet).
This project requires 24 panels, including 4 yellow ones for the nesting box.
Completion is achievable after 3 to 4 days of dedicated work.
![bscap0030-18b1ec8f559.jpg](./bscap0030-18b1ec8f559.jpg)
![20220805_103346-18b1ec92d75.jpg](./20220805_103346-18b1ec92d75.jpg)
![20220805_161737-18b1ec9434a.jpg](./20220805_161737-18b1ec9434a.jpg)
### Step 6: Build the wooden structure and the roof
### Construction Guide for Wooden Structure
Build the wooden structure according to the provided plans.
Adapt the design to suit your location and materials.
We used Trespa panels, available from excess stock, for the floor and ceiling. Alternatively, consider using plastic panels.
The roof is insulated and covered with corrugated iron sheets.
Plans include a separate storage area accessed from outside the main enclosure.
![20220727_171447-18b1ecd13d5.jpg](./20220727_171447-18b1ecd13d5.jpg)
![20220806_184108-18b1ecd2b49.jpg](./20220806_184108-18b1ecd2b49.jpg)
### Step 7: Cut and add your recycled plastic sheets
### Wall Cladding for Your Chicken Coop
Exercise caution when cutting panels; ensure the workspace permits the collection of any resulting plastic dust. Pre-drill holes to attach the panels to the wooden structure, and gather any plastic waste during this process.
![20220807_172729-18b1eef71b2.jpg](./20220807_172729-18b1eef71b2.jpg)
![20220807_172810-18b1eefea4b.jpg](./20220807_172810-18b1eefea4b.jpg)
![20220904180223_IMG_2623-18b1efda7f0.JPG](./20220904180223_IMG_2623-18b1efda7f0.JPG)
### Step 8: Allow space between your panels !
We did not allow space between the panels, leading to bulging in high heat. To prevent this, leave 0.2 in-0.4 in (0.5 cm-1 cm) between panels. Plan for seasonal temperature variations when constructing your henhouse, as they can affect panel expansion.
![begin-18b1eebc54f.jpg](./begin-18b1eebc54f.jpg)
![winter-18b1eebdaf4.jpg](./winter-18b1eebdaf4.jpg)
![spring-18b1eebf4fb.jpg](./spring-18b1eebf4fb.jpg)
### Step 9: Create your doors and windows
The doors and windows consist of a steel structure that we painted ourselves. Initially, we used putty to attach the panels to the steel frame, but it proved ineffective. Consequently, we switched to a mechanical fastening solution. We also installed metal mesh on the windows to prevent martens and rats from entering.
![20221014_090849-18b1ef361a7.jpg](./20221014_090849-18b1ef361a7.jpg)
![20221022_165327-18b1efa2685.jpg](./20221022_165327-18b1efa2685.jpg)
### Step 10: Now, the nests !
Build your nests by following the plans and adjusting them as needed. Feel free to choose any color you prefer.
![20221022_165351-18b1ef9963b.jpg](./20221022_165351-18b1ef9963b.jpg)
![20221022_165340-18b1ef9ee53.jpg](./20221022_165340-18b1ef9ee53.jpg)
![20221022_165359-18b1efb8b26.jpg](./20221022_165359-18b1efb8b26.jpg)
### Step 11: Add the last elements
If not yet completed, install the interior perch and the automatic door for the chickens (we used an Omlet brand door acquired second-hand). Adjust according to available materials.
![20221022_165315-18b1efdf8c3.jpg](./20221022_165315-18b1efdf8c3.jpg)
![20221022_165305-18b1efe25fe.jpg](./20221022_165305-18b1efe25fe.jpg)
![20221022_165332-18b1efe7fc8.jpg](./20221022_165332-18b1efe7fc8.jpg)
### Step 12: Time to celebrate !
Host a remarkable gathering with friends. If you construct a similar chicken coop, please share your photos.
![celebration-18b1f13c990.jpg](./celebration-18b1f13c990.jpg)
## Resources
### Software
- [LibreCAD](https://librecad.org/) for viewing/modifying .DXF plans
### Shredding Equipment
- V4 Pro shredder (multiple passes for size reduction)
### Washing & Drying Tools
- Industrial washing machines with microplastic filtration
- Water recovery systems for closed-loop cycles
- Tumble dryers
### Construction Hardware
- Trespa panels ([official site](https://www.trespa.com)) or plastic sheets for surfaces
- Corrugated iron sheets for roofing
- Steel frames for doors/windows
### Safety & Assembly
- Dust collection system for plastic cutting
- Power drill/driver for panel attachment
- Mechanical fasteners (replaces ineffective putty)
- Metal mesh for pest-proof window covers
- [Omlet automatic chicken door](https://www.omlet.com) (used model)
Key quantities: 240kg bottle caps, 24 panels (4 colored), 3-4 day build time.
## References
## Articles
- [Recycled Plastic Chicken Coop - The Hampton](https://eartheasy.com/recycled-plastic-chicken-coop-the-hampton/)
- [Nestera Chicken Coops | Plastic Chicken Houses For Sale](https://www.pipinchicksilkies.com/chicken-coops-runs/nestera-recycled-plastic-poultry-houses/)
- [Best Plastic Chicken Coops (2025)](https://www.chickenfans.com/best-plastic-chicken-coops/)
- [Building a Coop with Recycled Materials](https://www.backyardchickens.com/articles/building-a-coop-with-recycled-materials-an-environmentally-friendly-approach-to-poultry-keeping.78370/)
- [Recycled Plastic Chicken Houses](https://arkus.co.uk/recycled-plastic-chicken-houses/)
- [Nestera Plastic Chicken Houses](https://thechickenhousecompany.co.uk/collections/nestera-plastic-chicken-houses)
- [Plastic Chicken Coops for Sale](https://www.donedeal.ie/poultry-for-sale/plastic-chicken-coops/27205457)
- [7 Chicken Coop Ideas: Protective & Cheap Projects](https://diyprojects.ideas2live4.com/2016/07/21/alternative-chicken-coop-ideas/)
## YouTube
- [How to Build the Small Ground Coop](https://www.youtube.com/watch?v=9SkgNLIVGsA)
- [Mid-Century Modern Chicken Coop Build](https://www.youtube.com/watch?v=E_goHTrihfo)
- [Arkus Recycled Plastic Chicken Coop Review](https://www.youtube.com/watch?v=z4aB6TIj4v0)
## Opensource Designs
- Build Chicken Coop from Bottle Caps

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---
title: Build easy-to-wash chicken coop from bottle caps
slug: build-easy-to-wash-chicken-coop-from-bottle-caps
description: Recycled plastic sheets are ideal for chicken coops due to their ease of cleaning and resistance to parasites like poultry red mites. Here is how ours was built: Download the plans and watch the stages in the accompanying video.
tags: ["product","HDPE","sheetpress"]
category: Products
difficulty: Hard
time: 3-4 weeks
location: Houyet, Belgium
---
import { Image } from 'astro:assets'
# Build easy-to-wash chicken coop from bottle caps
<Image src={import('./20230522_140027-18b00b8c426.jpg')} alt="Build easy-to-wash chicken coop from bottle caps" />
Recycled plastic sheets are ideal for chicken coops due to their ease of cleaning and resistance to parasites like poultry red mites. Here is how ours was built: Download the plans and watch the stages in the accompanying video.
User Location: Houyet, Belgium
## Steps
### Step 1: Watch that amazing Youtube video first !
In this video, I demonstrate the production stages of a chicken coop made from plastic sheets. Watching the video will provide a comprehensive overview, making the process easier to follow.
### Step 2: Download the files provided above
The files contain henhouse plans in .PDF and .DXF formats for viewing and modification with open-source software like LibreCAD. The wooden structure is designed for panels measuring 39*39*0.4 inches (100*100*1 cm).
<Image src={import('./librecad-18b242fed04.jpg')} alt="librecad-18b242fed04.jpg" />
### Step 3: Collect around 120 000 bottle caps
Collecting a substantial number of caps can be challenging. Here is my approach:
I collaborate with an organization that gathers caps from schools, stores, and public places and sorts them by color. I pay for this service to save time.
Seek out similar organizations in your area. Often, these groups collect bottle caps and sell them, using the proceeds to support charitable activities such as providing guide dogs for the blind or wheelchairs for the disabled.
For this project, we required 240 kilograms (approximately 530 pounds) of bottle caps.
<Image src={import('./souffleunpeu2-18b1eafc264.jpg')} alt="souffleunpeu2-18b1eafc264.jpg" />
<Image src={import('./bscap0029-18b1ebf50dc.jpg')} alt="bscap0029-18b1ebf50dc.jpg" />
### Step 4: Shred & wash your bottle caps
### Shredding
I use a V4 pro shredder to process the caps four times until the shred meets my size requirements.
### Washing and Drying
Washing is more effective post-grinding. I place shredded plastic in durable cotton canvas bags, securing them with reusable zip-ties. These are washed in domestic machines equipped with filtration systems to prevent microplastic release and water recovery systems to recycle water efficiently.
Subsequently, I dry the shredded material in tumble dryers to ensure it is completely dry.
<Image src={import('./20220912_130432_3-18b1eb620eb.jpg')} alt="20220912_130432 (3)-18b1eb620eb.jpg" />
<Image src={import('./20220912_130442_1-18b1eb63475.jpg')} alt="20220912_130442 (1)-18b1eb63475.jpg" />
<Image src={import('./bscap0026-18b1eba04f6.jpg')} alt="bscap0026-18b1eba04f6.jpg" />
### Step 5: Create your sheets using the sheetpress
By following the previously explained method, you can produce approximately 6 to 8 sheets per day (2.5 to 3.5 square feet).
This project requires 24 panels, including 4 yellow ones for the nesting box.
Completion is achievable after 3 to 4 days of dedicated work.
<Image src={import('./bscap0030-18b1ec8f559.jpg')} alt="bscap0030-18b1ec8f559.jpg" />
<Image src={import('./20220805_103346-18b1ec92d75.jpg')} alt="20220805_103346-18b1ec92d75.jpg" />
<Image src={import('./20220805_161737-18b1ec9434a.jpg')} alt="20220805_161737-18b1ec9434a.jpg" />
### Step 6: Build the wooden structure and the roof
### Construction Guide for Wooden Structure
Build the wooden structure according to the provided plans.
Adapt the design to suit your location and materials.
We used Trespa panels, available from excess stock, for the floor and ceiling. Alternatively, consider using plastic panels.
The roof is insulated and covered with corrugated iron sheets.
Plans include a separate storage area accessed from outside the main enclosure.
<Image src={import('./20220727_171447-18b1ecd13d5.jpg')} alt="20220727_171447-18b1ecd13d5.jpg" />
<Image src={import('./20220806_184108-18b1ecd2b49.jpg')} alt="20220806_184108-18b1ecd2b49.jpg" />
### Step 7: Cut and add your recycled plastic sheets
### Wall Cladding for Your Chicken Coop
Exercise caution when cutting panels; ensure the workspace permits the collection of any resulting plastic dust. Pre-drill holes to attach the panels to the wooden structure, and gather any plastic waste during this process.
<Image src={import('./20220807_172729-18b1eef71b2.jpg')} alt="20220807_172729-18b1eef71b2.jpg" />
<Image src={import('./20220807_172810-18b1eefea4b.jpg')} alt="20220807_172810-18b1eefea4b.jpg" />
<Image src={import('./20220904180223_IMG_2623-18b1efda7f0.JPG')} alt="20220904180223_IMG_2623-18b1efda7f0.JPG" />
### Step 8: Allow space between your panels !
We did not allow space between the panels, leading to bulging in high heat. To prevent this, leave 0.2 in-0.4 in (0.5 cm-1 cm) between panels. Plan for seasonal temperature variations when constructing your henhouse, as they can affect panel expansion.
<Image src={import('./begin-18b1eebc54f.jpg')} alt="begin-18b1eebc54f.jpg" />
<Image src={import('./winter-18b1eebdaf4.jpg')} alt="winter-18b1eebdaf4.jpg" />
<Image src={import('./spring-18b1eebf4fb.jpg')} alt="spring-18b1eebf4fb.jpg" />
### Step 9: Create your doors and windows
The doors and windows consist of a steel structure that we painted ourselves. Initially, we used putty to attach the panels to the steel frame, but it proved ineffective. Consequently, we switched to a mechanical fastening solution. We also installed metal mesh on the windows to prevent martens and rats from entering.
<Image src={import('./20221014_090849-18b1ef361a7.jpg')} alt="20221014_090849-18b1ef361a7.jpg" />
<Image src={import('./20221022_165327-18b1efa2685.jpg')} alt="20221022_165327-18b1efa2685.jpg" />
### Step 10: Now, the nests !
Build your nests by following the plans and adjusting them as needed. Feel free to choose any color you prefer.
<Image src={import('./20221022_165351-18b1ef9963b.jpg')} alt="20221022_165351-18b1ef9963b.jpg" />
<Image src={import('./20221022_165340-18b1ef9ee53.jpg')} alt="20221022_165340-18b1ef9ee53.jpg" />
<Image src={import('./20221022_165359-18b1efb8b26.jpg')} alt="20221022_165359-18b1efb8b26.jpg" />
### Step 11: Add the last elements
If not yet completed, install the interior perch and the automatic door for the chickens (we used an Omlet brand door acquired second-hand). Adjust according to available materials.
<Image src={import('./20221022_165315-18b1efdf8c3.jpg')} alt="20221022_165315-18b1efdf8c3.jpg" />
<Image src={import('./20221022_165305-18b1efe25fe.jpg')} alt="20221022_165305-18b1efe25fe.jpg" />
<Image src={import('./20221022_165332-18b1efe7fc8.jpg')} alt="20221022_165332-18b1efe7fc8.jpg" />
### Step 12: Time to celebrate !
Host a remarkable gathering with friends. If you construct a similar chicken coop, please share your photos.
<Image src={import('./celebration-18b1f13c990.jpg')} alt="celebration-18b1f13c990.jpg" />

20
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## Articles
- [Recycled Plastic Chicken Coop - The Hampton](https://eartheasy.com/recycled-plastic-chicken-coop-the-hampton/)
- [Nestera Chicken Coops | Plastic Chicken Houses For Sale](https://www.pipinchicksilkies.com/chicken-coops-runs/nestera-recycled-plastic-poultry-houses/)
- [Best Plastic Chicken Coops (2025)](https://www.chickenfans.com/best-plastic-chicken-coops/)
- [Building a Coop with Recycled Materials](https://www.backyardchickens.com/articles/building-a-coop-with-recycled-materials-an-environmentally-friendly-approach-to-poultry-keeping.78370/)
- [Recycled Plastic Chicken Houses](https://arkus.co.uk/recycled-plastic-chicken-houses/)
- [Nestera Plastic Chicken Houses](https://thechickenhousecompany.co.uk/collections/nestera-plastic-chicken-houses)
- [Plastic Chicken Coops for Sale](https://www.donedeal.ie/poultry-for-sale/plastic-chicken-coops/27205457)
- [7 Chicken Coop Ideas: Protective & Cheap Projects](https://diyprojects.ideas2live4.com/2016/07/21/alternative-chicken-coop-ideas/)
## YouTube
- [How to Build the Small Ground Coop](https://www.youtube.com/watch?v=9SkgNLIVGsA)
- [Mid-Century Modern Chicken Coop Build](https://www.youtube.com/watch?v=E_goHTrihfo)
- [Arkus Recycled Plastic Chicken Coop Review](https://www.youtube.com/watch?v=z4aB6TIj4v0)
## Opensource Designs
- Build Chicken Coop from Bottle Caps

29
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@ -0,0 +1,29 @@
### Software
- [LibreCAD](https://librecad.org/) for viewing/modifying .DXF plans
### Shredding Equipment
- V4 Pro shredder (multiple passes for size reduction)
### Washing & Drying Tools
- Industrial washing machines with microplastic filtration
- Water recovery systems for closed-loop cycles
- Tumble dryers
### Construction Hardware
- Trespa panels ([official site](https://www.trespa.com)) or plastic sheets for surfaces
- Corrugated iron sheets for roofing
- Steel frames for doors/windows
### Safety & Assembly
- Dust collection system for plastic cutting
- Power drill/driver for panel attachment
- Mechanical fasteners (replaces ineffective putty)
- Metal mesh for pest-proof window covers
- [Omlet automatic chicken door](https://www.omlet.com) (used model)
Key quantities: 240kg bottle caps, 24 panels (4 colored), 3-4 day build time.

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---
title: Build your own filament cooling system
slug: build-your-own-filament-cooling-system-
description: # JARVIS Airpath Cooling System Assembly Guide
## Contents
1. Airpath Components (PDF)
2. Airpath 3D Printed Parts (ZIP)
## Instructions
Assemble your JARVIS Airpath cooling system in six simple steps.
For assistance, access our video tutorial:
[Watch Video](https://youtu.be/6Ae6oDKhqiE)
For further information, visit our website:
[Visit Qitech](https://www.qitech.de/en/industries)
tags: ["extrusion","untagged","melting","product"]
category: Machines
difficulty: Easy
time: < 1 hour
keywords: JARVIS Airpath, cooling system assembly, assembly guide, Qitech, magnetic clips, gondolas, aluminum profiles, fan installation, control box, DC jack
location: Darmstadt, Germany
---
# Build your own filament cooling system
![Build your own filament cooling system ](Screenshot_2023-06-14_162618-188ba4d4380.png)
# JARVIS Airpath Cooling System Assembly Guide
## Contents
1. Airpath Components (PDF)
2. Airpath 3D Printed Parts (ZIP)
## Instructions
Assemble your JARVIS Airpath cooling system in six simple steps.
For assistance, access our video tutorial:
[Watch Video](https://youtu.be/6Ae6oDKhqiE)
For further information, visit our website:
[Visit Qitech](https://www.qitech.de/en/industries)
User Location: Darmstadt, Germany
## Steps
### Step 1: Preparation of the gondolas
First, prepare the four gondolas by inserting the included magnets into the upper holes. Ensure all magnets in the gondolas have the same polarity for proper interaction with the magnetic clips.
The clips contain two interior holes for magnets. Insert the magnets with the correct orientation to ensure they attract the gondolas.
![IMG_1250-188ba169e65.jpg](./IMG_1250-188ba169e65.jpg)
![IMG_1249-188ba170773.jpg](./IMG_1249-188ba170773.jpg)
![20230614_135324-188ba2346cd.jpg](./20230614_135324-188ba2346cd.jpg)
### Step 2: Attachment of the gondolas to the aluminum profile
Attach the four gondolas to the aluminum profiles using 16 M5 x 8 screws and 16 T-nuts. You will need a 3 mm (0.12 in) Allen key.
Ensure the front side is visible and accessible; the aluminum profiles have a designated hole for this. Slide the T-nuts into the profiles, with the rounded side facing down. Secure the gondolas to the profiles with the screws, following the specified order. The outer gondolas should have their logos facing outwards, and the inner ones should show labeling. Make sure gondolas do not extend past the aluminum profiles—these should extend about 2 mm (0.08 in) outward.
![20230614_135644-188ba262af1.jpg](./20230614_135644-188ba262af1.jpg)
![20230602_135604-188ba264364.jpg](./20230602_135604-188ba264364.jpg)
![20230602_155106-188ba2692e5.jpg](./20230602_155106-188ba2692e5.jpg)
### Step 3: Insertion of fans
Insert the fans into the JARVIS Airpath, ensuring the cone tips face inward and the display cables are pulled through the aluminum profile (aluminium profile), ensuring cables do not impede fan rotation. Secure the grilles and fans onto the gondola.
![20230614_154834-188ba3f57a3.jpg](./20230614_154834-188ba3f57a3.jpg)
![20230606_135846-188ba2d0d2c.jpg](./20230606_135846-188ba2d0d2c.jpg)
![20230606_143841-188ba2d92c4.jpg](./20230606_143841-188ba2d92c4.jpg)
### Step 4: Attaching the support feet
To securely screw in the feet, you will need 4 T-nuts, 4 hard plastic washers, 4 rubber feet, 4 screws (M5 x 14 or 0.2 x 0.55 inches), and a 4 mm (0.16 inch) Allen key.
Place the JARVIS Airpath on the rubber feet. Position the hard plastic washers between the rubber feet and the aluminum profile. Screw two support feet into the aluminum profile.
![20230614_140329-188ba37bc1d.jpg](./20230614_140329-188ba37bc1d.jpg)
![20230602_135914-188ba387d56.jpg](./20230602_135914-188ba387d56.jpg)
![20230602_140104-188ba3ed110.jpg](./20230602_140104-188ba3ed110.jpg)
### Step 5: Attaching the control box
Attach the control box using four T-nuts and four M5 x 8 (5/16 in x 5/16 in) screws. Insert the T-nuts into the aluminum profile and secure the control box to the front. Ensure power cables are routed through the hole into the box.
![IMG_1247(1)-188ba3ce499.jpg](./IMG_12471-188ba3ce499.jpg)
![IMG_1159(2)-188ba3dad97.jpg](./IMG_11592-188ba3dad97.jpg)
![IMG_1161(2)-188ba3e58b4.jpg](./IMG_11612-188ba3e58b4.jpg)
### Step 6: Completion of the control box
You need the control cover, display box, DC jack, four set screws, an Allen wrench (2.5 mm/0.1 in), and a small screwdriver (0.35 mm/2.5 mm or 0.014 in/0.098 in).
Open the display box and remove the green start button.
Attach the display to the control cover, ensuring the black border faces downward. Insert the fan control through the smaller hole and the green start button through the larger hole, securing it with a thin metal ring and nut.
Install the DC jack through the side hole of the control box and thread the cables into the box.
Screw the black cables into the "-" terminal and the red cables into the "+" terminal before closing the box.
Use set screws to secure the control box to the display cover.
![20230614_140842-188ba392e9a.jpg](./20230614_140842-188ba392e9a.jpg)
![IMG_1242-188ba3b92f4.jpg](./IMG_1242-188ba3b92f4.jpg)
![20230609_105029-188ba3b6389.jpg](./20230609_105029-188ba3b6389.jpg)
## Resources
## Tools
- 3 mm (0.12 in) Allen key [Source](https://youtu.be/6Ae6oDKhqiE)
- 4 mm (0.16 in) Allen key [Source](https://youtu.be/6Ae6oDKhqiE)
- 2.5 mm (0.1 in) Allen wrench [Source](https://youtu.be/6Ae6oDKhqiE)
- 0.35 mm/2.5 mm (0.014 in/0.098 in) screwdriver [Source](https://youtu.be/6Ae6oDKhqiE)
## Hardware
- Magnets (for gondolas/clips) [Source](https://youtu.be/6Ae6oDKhqiE)
- M5 x 8 screws (16x) + T-nuts (16x) [Source](https://youtu.be/6Ae6oDKhqiE)
- M5 x 14 screws (4x) + rubber feet (4x) [Source](https://youtu.be/6Ae6oDKhqiE)
- Control box + DC jack [Source](https://youtu.be/6Ae6oDKhqiE)
- Aluminum profiles + fans/grilles [Source](https://youtu.be/6Ae6oDKhqiE)
## Software
- Airpath Components PDF [Source](https://www.qitech.de/en/industries)
- Airpath 3D Printed Parts ZIP [Source](https://www.qitech.de/en/industries)
- Assembly video tutorial [Source](https://youtu.be/6Ae6oDKhqiE)
- Qitech support portal [Source](https://www.qitech.de/en/industries)
## References
## YouTube
- [JARVIS Airpath Assembly Tutorial](https://youtu.be/6Ae6oDKhqiE)
## Articles
- [Qitech Industries](https://www.qitech.de/en/industries)

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---
title: Build your own filament cooling system
slug: build-your-own-filament-cooling-system-
description: # JARVIS Airpath Cooling System Assembly Guide
## Contents
1. Airpath Components (PDF)
2. Airpath 3D Printed Parts (ZIP)
## Instructions
Assemble your JARVIS Airpath cooling system in six simple steps.
For assistance, access our video tutorial:
[Watch Video](https://youtu.be/6Ae6oDKhqiE)
For further information, visit our website:
[Visit Qitech](https://www.qitech.de/en/industries)
tags: ["extrusion","untagged","melting","product"]
category: Machines
difficulty: Easy
time: < 1 hour
location: Darmstadt, Germany
---
import { Image } from 'astro:assets'
# Build your own filament cooling system
<Image src={import('./Screenshot_2023-06-14_162618-188ba4d4380.png')} alt="Build your own filament cooling system " />
# JARVIS Airpath Cooling System Assembly Guide
## Contents
1. Airpath Components (PDF)
2. Airpath 3D Printed Parts (ZIP)
## Instructions
Assemble your JARVIS Airpath cooling system in six simple steps.
For assistance, access our video tutorial:
[Watch Video](https://youtu.be/6Ae6oDKhqiE)
For further information, visit our website:
[Visit Qitech](https://www.qitech.de/en/industries)
User Location: Darmstadt, Germany
## Steps
### Step 1: Preparation of the gondolas
First, prepare the four gondolas by inserting the included magnets into the upper holes. Ensure all magnets in the gondolas have the same polarity for proper interaction with the magnetic clips.
The clips contain two interior holes for magnets. Insert the magnets with the correct orientation to ensure they attract the gondolas.
<Image src={import('./IMG_1250-188ba169e65.jpg')} alt="IMG_1250-188ba169e65.jpg" />
<Image src={import('./IMG_1249-188ba170773.jpg')} alt="IMG_1249-188ba170773.jpg" />
<Image src={import('./20230614_135324-188ba2346cd.jpg')} alt="20230614_135324-188ba2346cd.jpg" />
### Step 2: Attachment of the gondolas to the aluminum profile
Attach the four gondolas to the aluminum profiles using 16 M5 x 8 screws and 16 T-nuts. You will need a 3 mm (0.12 in) Allen key.
Ensure the front side is visible and accessible; the aluminum profiles have a designated hole for this. Slide the T-nuts into the profiles, with the rounded side facing down. Secure the gondolas to the profiles with the screws, following the specified order. The outer gondolas should have their logos facing outwards, and the inner ones should show labeling. Make sure gondolas do not extend past the aluminum profiles—these should extend about 2 mm (0.08 in) outward.
<Image src={import('./20230614_135644-188ba262af1.jpg')} alt="20230614_135644-188ba262af1.jpg" />
<Image src={import('./20230602_135604-188ba264364.jpg')} alt="20230602_135604-188ba264364.jpg" />
<Image src={import('./20230602_155106-188ba2692e5.jpg')} alt="20230602_155106-188ba2692e5.jpg" />
### Step 3: Insertion of fans
Insert the fans into the JARVIS Airpath, ensuring the cone tips face inward and the display cables are pulled through the aluminum profile (aluminium profile), ensuring cables do not impede fan rotation. Secure the grilles and fans onto the gondola.
<Image src={import('./20230614_154834-188ba3f57a3.jpg')} alt="20230614_154834-188ba3f57a3.jpg" />
<Image src={import('./20230606_135846-188ba2d0d2c.jpg')} alt="20230606_135846-188ba2d0d2c.jpg" />
<Image src={import('./20230606_143841-188ba2d92c4.jpg')} alt="20230606_143841-188ba2d92c4.jpg" />
### Step 4: Attaching the support feet
To securely screw in the feet, you will need 4 T-nuts, 4 hard plastic washers, 4 rubber feet, 4 screws (M5 x 14 or 0.2 x 0.55 inches), and a 4 mm (0.16 inch) Allen key.
Place the JARVIS Airpath on the rubber feet. Position the hard plastic washers between the rubber feet and the aluminum profile. Screw two support feet into the aluminum profile.
<Image src={import('./20230614_140329-188ba37bc1d.jpg')} alt="20230614_140329-188ba37bc1d.jpg" />
<Image src={import('./20230602_135914-188ba387d56.jpg')} alt="20230602_135914-188ba387d56.jpg" />
<Image src={import('./20230602_140104-188ba3ed110.jpg')} alt="20230602_140104-188ba3ed110.jpg" />
### Step 5: Attaching the control box
Attach the control box using four T-nuts and four M5 x 8 (5/16 in x 5/16 in) screws. Insert the T-nuts into the aluminum profile and secure the control box to the front. Ensure power cables are routed through the hole into the box.
<Image src={import('./IMG_12471-188ba3ce499.jpg')} alt="IMG_1247(1)-188ba3ce499.jpg" />
<Image src={import('./IMG_11592-188ba3dad97.jpg')} alt="IMG_1159(2)-188ba3dad97.jpg" />
<Image src={import('./IMG_11612-188ba3e58b4.jpg')} alt="IMG_1161(2)-188ba3e58b4.jpg" />
### Step 6: Completion of the control box
You need the control cover, display box, DC jack, four set screws, an Allen wrench (2.5 mm/0.1 in), and a small screwdriver (0.35 mm/2.5 mm or 0.014 in/0.098 in).
Open the display box and remove the green start button.
Attach the display to the control cover, ensuring the black border faces downward. Insert the fan control through the smaller hole and the green start button through the larger hole, securing it with a thin metal ring and nut.
Install the DC jack through the side hole of the control box and thread the cables into the box.
Screw the black cables into the "-" terminal and the red cables into the "+" terminal before closing the box.
Use set screws to secure the control box to the display cover.
<Image src={import('./20230614_140842-188ba392e9a.jpg')} alt="20230614_140842-188ba392e9a.jpg" />
<Image src={import('./IMG_1242-188ba3b92f4.jpg')} alt="IMG_1242-188ba3b92f4.jpg" />
<Image src={import('./20230609_105029-188ba3b6389.jpg')} alt="20230609_105029-188ba3b6389.jpg" />

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## YouTube
- [JARVIS Airpath Assembly Tutorial](https://youtu.be/6Ae6oDKhqiE)
## Articles
- [Qitech Industries](https://www.qitech.de/en/industries)

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## Tools
- 3 mm (0.12 in) Allen key [Source](https://youtu.be/6Ae6oDKhqiE)
- 4 mm (0.16 in) Allen key [Source](https://youtu.be/6Ae6oDKhqiE)
- 2.5 mm (0.1 in) Allen wrench [Source](https://youtu.be/6Ae6oDKhqiE)
- 0.35 mm/2.5 mm (0.014 in/0.098 in) screwdriver [Source](https://youtu.be/6Ae6oDKhqiE)
## Hardware
- Magnets (for gondolas/clips) [Source](https://youtu.be/6Ae6oDKhqiE)
- M5 x 8 screws (16x) + T-nuts (16x) [Source](https://youtu.be/6Ae6oDKhqiE)
- M5 x 14 screws (4x) + rubber feet (4x) [Source](https://youtu.be/6Ae6oDKhqiE)
- Control box + DC jack [Source](https://youtu.be/6Ae6oDKhqiE)
- Aluminum profiles + fans/grilles [Source](https://youtu.be/6Ae6oDKhqiE)
## Software
- Airpath Components PDF [Source](https://www.qitech.de/en/industries)
- Airpath 3D Printed Parts ZIP [Source](https://www.qitech.de/en/industries)
- Assembly video tutorial [Source](https://youtu.be/6Ae6oDKhqiE)
- Qitech support portal [Source](https://www.qitech.de/en/industries)

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---
title: Clothes Hanger Mould
slug: clothes-hanger-mould-25116
description: This is a CNC machined mold. Locate a suitable CNC provider and get ready to produce numerous hangers.
tags: ["PP","HDPE","LDPE","mould","PS","injection"]
category: Moulds
difficulty: Hard
time: 1-2 weeks
keywords: CNC machining, mold fabrication, aluminum blocks, CNC provider, Bogota CNC services, flange connection guide, Solidworks mold design, nozzle customization, acid etching process, hanger production.
location: Bogota, Colombia
---
# Clothes Hanger Mould
![Clothes Hanger Mould](5b-18c32101a6f.jpg)
This is a CNC machined mold. Locate a suitable CNC provider and get ready to produce numerous hangers.
User Location: Bogota, Colombia
## Steps
### Step 1: Download the files
Into the files, you will find:
- General drawings
- .IGES files
- .STEP files
- Parasolid files
- Solidworks editable file
![files-18c32a15136.png](./files-18c32a15136.png)
![sw-18c32a16e87.png](./sw-18c32a16e87.png)
![draw-18c32a17d9c.jpg](./draw-18c32a17d9c.jpg)
### Step 2: Machine your mould
For the mold, two aluminum blocks measuring 430mm by 255mm by 25mm (16.93in by 10.04in by 0.98in) are required.
Contact a CNC machinist to fabricate the design files.
You can opt to include a cutout for a logo or keep it flat (both options are available for download).
For customization, modify the dimensions or other design aspects using the editable software file. Please share any innovations.
### Step 3: Select the nozzle
### Nozzle and Flange Connection Guide
Select the appropriate flange for your machine nozzle to connect it to the mold.
- **Conical Nozzle**: Use a flat 0.24-inch (6mm) flange with a bevel to receive the nozzle. Ensure it aligns with the screw heads through slots. It is not attached to the mold but pressed with a jack between the mold and nozzle.
- **Screw Nozzle**: Weld the pipe connector to the flange and secure the flange to the mold using closing screws.
Adjust the design as necessary to suit your requirements.
![conic-18c325bb51e.png](./conic-18c325bb51e.png)
![thread-18c325bc74d.png](./thread-18c325bc74d.png)
### Step 4: Add the logo
If you decide to include logos in the mold, add the engraved sheet.
In this example, a metal sheet is engraved using acid etching, a process used in printing.
Trim and file the sheet to its final size, then fit it into the hole.
![IMG_20231126_165118811-18c328e0186.jpg](./IMG_20231126_165118811-18c328e0186.jpg)
![IMG_20231126_165207756-18c3290a2f8.jpg](./IMG_20231126_165207756-18c3290a2f8.jpg)
![IMG_20231126_170349738-18c3290bf54.jpg](./IMG_20231126_170349738-18c3290bf54.jpg)
### Step 5: Inject your hangers!
Heat the machine, insert the plastic, and inject to create your hangers.
The final weight is approximately 81 grams (2.86 ounces).
![aaa-18c3299769c.jpg](./aaa-18c3299769c.jpg)
![IMG_20231126_174656988-18c3292dc79.jpg](./IMG_20231126_174656988-18c3292dc79.jpg)
![IMG_20231126_172100313-18c3293aad6.jpg](./IMG_20231126_172100313-18c3293aad6.jpg)
## Resources
To facilitate the CNC mold production and injection molding process described, here are the essential components and resources:
### Tools & Machinery
- CNC machining services ([Thomasnet Directory](https://www.thomasnet.com/products/cnc-machining-95380005-1.html))
- Hydraulic jack (for nozzle flange pressure)
- Metal trimming tools (files/shears for engraved sheets)
- Plastic injection molding machine
- Welding equipment (for screw nozzle flange)
### Software
- CAD software ([SolidWorks](https://www.solidworks.com))
- File-compatible viewers for IGES/STEP/Parasolid (e.g., [AutoCAD](https://www.autodesk.com))
- Vector graphic software for logos ([Adobe Illustrator](https://www.adobe.com))
### Hardware
- Aluminum blocks (430×255×25mm / 16.93×10.04×0.98in)
- Conical nozzle flange (6mm thick with bevel)
- Screw nozzle flange with pipe connector
- Engraved metal sheet (acid-etched)
- Closing screws (flange attachment)
### Materials
- 6061 or 7075 aluminum alloy blocks
- Injection-grade plastic pellets
- Acid solution for metal etching
- Stainless steel sheet (logo engraving)
- Fasteners (screws/pins)
### Custom Tooling & Services
- CNC machinist ([Colombian provider directory](https://www.alibaba.com/co/cnc-machining-services))
- Acid etching service (~~[Local print shops](https://www.hubs.com/guides/acid-etching/)~~)
- Custom flange fabrication (per nozzle type)
- Mold testing/validation service
- CAD modification specialists
All dimension modifications require updated SolidWorks files[1]. For Bogotá-specific machining options, consider industrial zones like Zona Franca de Bogotá[3]. Ensure aluminum blocks meet MIL-A-22771 standards for injection molds[2].
## References
## References
### Articles
- [CNC machines for efficiency in mold manufacturing - Thriam](https://thriam.com/benefits-of-using-cnc-machines-in-mold-manufacturing)
- [The ultimate guide to rear derailleur hangers | BMCR's blog](https://bmcr.com.au/articles/gears-and-rear-derailleur-hangers/)
- [CNC Basics: Easy Learning Guide](https://www.cnccookbook.com/learn-cnc-basics-tutorial/)
- [Helpful Injection Molding Design Guidelines | GrabCAD Tutorials](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)
- [What are the CNC Techniques in Mold Making? - JTR China](https://www.jtrmachine.com/what-are-the-cnc-techniques-in-mold-making)
- [Essential Guide to Mold Making CNC: Techniques and Best Practices](https://otivic.com/mold-making-cnc/)
### Books
- ~~[CNC Handbook | McGraw-Hill Education](https://www.accessengineeringlibrary.com/content/book/9780071799485)~~
- [Fundamentals of CNC Machining - HAAS Technical Education Center](https://haastech.tamu.edu/wp-content/uploads/sites/5/2016/05/Autodesk_CNCBOOK.pdf)
- [The Homebrew Industrial Revolution](https://apw.org.nz/wp-content/uploads/2015/06/HomeBrewRevolution_Carson.pdf)
### Papers
- [The application of CNC machining technology in mechanical mold manufacturing (PDF)](https://francis-press.com/uploads/papers/I7g2oo6Yab8ZzBwUrlFqm4D1tMGRF4dXAhrYu2Xe.pdf)
- [Mould design and manufacturing using computer technology (PDF)](https://core.ac.uk/download/pdf/148644219.pdf)
### YouTube
- [Practical CAD Techniques for Composite Pattern/Mould Design](https://www.youtube.com/watch?v=dDqTGr8NW7A)
- [How Wood Skateboard Molds are Made (CNC)](https://www.youtube.com/watch?v=-zVujT_tuKU)
- [Beginner To Advanced — How To Create a Mold— Part 1](https://www.youtube.com/watch?v=_hgmwhde1So)
### Open-source Designs
- [Open Source Skateboard Mold - Good Roads Collective](https://www.goodroadscollective.com/open-source-skateboard-mold)

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"text": "Heat the machine, insert the plastic, and inject to create your hangers.\n\nThe final weight is approximately 81 grams (2.86 ounces).",
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"content": "This is a CNC machined mold. Locate a suitable CNC provider and get ready to produce numerous hangers.\n\n\nUser Location: Bogota, Colombia\n\nInto the files, you will find:\n\n- General drawings\n- .IGES files\n- .STEP files\n- Parasolid files\n- Solidworks editable file\n\nFor the mold, two aluminum blocks measuring 430mm by 255mm by 25mm (16.93in by 10.04in by 0.98in) are required.\n\nContact a CNC machinist to fabricate the design files.\n\nYou can opt to include a cutout for a logo or keep it flat (both options are available for download).\n\nFor customization, modify the dimensions or other design aspects using the editable software file. Please share any innovations.\n\n### Nozzle and Flange Connection Guide\n\nSelect the appropriate flange for your machine nozzle to connect it to the mold.\n\n- **Conical Nozzle**: Use a flat 0.24-inch (6mm) flange with a bevel to receive the nozzle. Ensure it aligns with the screw heads through slots. It is not attached to the mold but pressed with a jack between the mold and nozzle.\n\n- **Screw Nozzle**: Weld the pipe connector to the flange and secure the flange to the mold using closing screws. \n\nAdjust the design as necessary to suit your requirements.\n\nIf you decide to include logos in the mold, add the engraved sheet.\n\nIn this example, a metal sheet is engraved using acid etching, a process used in printing.\n\nTrim and file the sheet to its final size, then fit it into the hole.\n\nHeat the machine, insert the plastic, and inject to create your hangers.\n\nThe final weight is approximately 81 grams (2.86 ounces).",
"keywords": "CNC machining, mold fabrication, aluminum blocks, CNC provider, Bogota CNC services, flange connection guide, Solidworks mold design, nozzle customization, acid etching process, hanger production.",
"resources": "To facilitate the CNC mold production and injection molding process described, here are the essential components and resources:\n\n### Tools & Machinery\n\n- CNC machining services ([Thomasnet Directory](https://www.thomasnet.com/products/cnc-machining-95380005-1.html))\n- Hydraulic jack (for nozzle flange pressure)\n- Metal trimming tools (files/shears for engraved sheets)\n- Plastic injection molding machine\n- Welding equipment (for screw nozzle flange)\n\n### Software\n\n- CAD software ([SolidWorks](https://www.solidworks.com))\n- File-compatible viewers for IGES/STEP/Parasolid (e.g., [AutoCAD](https://www.autodesk.com))\n- Vector graphic software for logos ([Adobe Illustrator](https://www.adobe.com))\n\n### Hardware\n\n- Aluminum blocks (430×255×25mm / 16.93×10.04×0.98in)\n- Conical nozzle flange (6mm thick with bevel)\n- Screw nozzle flange with pipe connector\n- Engraved metal sheet (acid-etched)\n- Closing screws (flange attachment)\n\n### Materials\n\n- 6061 or 7075 aluminum alloy blocks\n- Injection-grade plastic pellets\n- Acid solution for metal etching\n- Stainless steel sheet (logo engraving)\n- Fasteners (screws/pins)\n\n### Custom Tooling & Services\n\n- CNC machinist ([Colombian provider directory](https://www.alibaba.com/co/cnc-machining-services))\n- Acid etching service (~~[Local print shops](https://www.hubs.com/guides/acid-etching/)~~)\n- Custom flange fabrication (per nozzle type)\n- Mold testing/validation service\n- CAD modification specialists\n\nAll dimension modifications require updated SolidWorks files[1]. For Bogotá-specific machining options, consider industrial zones like Zona Franca de Bogotá[3]. Ensure aluminum blocks meet MIL-A-22771 standards for injection molds[2].",
"references": "## References\n\n### Articles\n\n- [CNC machines for efficiency in mold manufacturing - Thriam](https://thriam.com/benefits-of-using-cnc-machines-in-mold-manufacturing)\n- [The ultimate guide to rear derailleur hangers | BMCR's blog](https://bmcr.com.au/articles/gears-and-rear-derailleur-hangers/)\n- [CNC Basics: Easy Learning Guide](https://www.cnccookbook.com/learn-cnc-basics-tutorial/)\n- [Helpful Injection Molding Design Guidelines | GrabCAD Tutorials](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)\n- [What are the CNC Techniques in Mold Making? - JTR China](https://www.jtrmachine.com/what-are-the-cnc-techniques-in-mold-making)\n- [Essential Guide to Mold Making CNC: Techniques and Best Practices](https://otivic.com/mold-making-cnc/)\n\n### Books\n\n- ~~[CNC Handbook | McGraw-Hill Education](https://www.accessengineeringlibrary.com/content/book/9780071799485)~~\n- [Fundamentals of CNC Machining - HAAS Technical Education Center](https://haastech.tamu.edu/wp-content/uploads/sites/5/2016/05/Autodesk_CNCBOOK.pdf)\n- [The Homebrew Industrial Revolution](https://apw.org.nz/wp-content/uploads/2015/06/HomeBrewRevolution_Carson.pdf)\n\n### Papers\n\n- [The application of CNC machining technology in mechanical mold manufacturing (PDF)](https://francis-press.com/uploads/papers/I7g2oo6Yab8ZzBwUrlFqm4D1tMGRF4dXAhrYu2Xe.pdf)\n- [Mould design and manufacturing using computer technology (PDF)](https://core.ac.uk/download/pdf/148644219.pdf)\n\n### YouTube\n\n- [Practical CAD Techniques for Composite Pattern/Mould Design](https://www.youtube.com/watch?v=dDqTGr8NW7A)\n- [How Wood Skateboard Molds are Made (CNC)](https://www.youtube.com/watch?v=-zVujT_tuKU)\n- [Beginner To Advanced — How To Create a Mold— Part 1](https://www.youtube.com/watch?v=_hgmwhde1So)\n\n### Open-source Designs\n\n- [Open Source Skateboard Mold - Good Roads Collective](https://www.goodroadscollective.com/open-source-skateboard-mold)"
}

95
howtos/clothes-hanger-mould-25116/index.mdx Normal file
View File

@ -0,0 +1,95 @@
---
title: Clothes Hanger Mould
slug: clothes-hanger-mould-25116
description: This is a CNC machined mold. Locate a suitable CNC provider and get ready to produce numerous hangers.
tags: ["PP","HDPE","LDPE","mould","PS","injection"]
category: Moulds
difficulty: Hard
time: 1-2 weeks
location: Bogota, Colombia
---
import { Image } from 'astro:assets'
# Clothes Hanger Mould
<Image src={import('./5b-18c32101a6f.jpg')} alt="Clothes Hanger Mould" />
This is a CNC machined mold. Locate a suitable CNC provider and get ready to produce numerous hangers.
User Location: Bogota, Colombia
## Steps
### Step 1: Download the files
Into the files, you will find:
- General drawings
- .IGES files
- .STEP files
- Parasolid files
- Solidworks editable file
<Image src={import('./files-18c32a15136.png')} alt="files-18c32a15136.png" />
<Image src={import('./sw-18c32a16e87.png')} alt="sw-18c32a16e87.png" />
<Image src={import('./draw-18c32a17d9c.jpg')} alt="draw-18c32a17d9c.jpg" />
### Step 2: Machine your mould
For the mold, two aluminum blocks measuring 430mm by 255mm by 25mm (16.93in by 10.04in by 0.98in) are required.
Contact a CNC machinist to fabricate the design files.
You can opt to include a cutout for a logo or keep it flat (both options are available for download).
For customization, modify the dimensions or other design aspects using the editable software file. Please share any innovations.
### Step 3: Select the nozzle
### Nozzle and Flange Connection Guide
Select the appropriate flange for your machine nozzle to connect it to the mold.
- **Conical Nozzle**: Use a flat 0.24-inch (6mm) flange with a bevel to receive the nozzle. Ensure it aligns with the screw heads through slots. It is not attached to the mold but pressed with a jack between the mold and nozzle.
- **Screw Nozzle**: Weld the pipe connector to the flange and secure the flange to the mold using closing screws.
Adjust the design as necessary to suit your requirements.
<Image src={import('./conic-18c325bb51e.png')} alt="conic-18c325bb51e.png" />
<Image src={import('./thread-18c325bc74d.png')} alt="thread-18c325bc74d.png" />
### Step 4: Add the logo
If you decide to include logos in the mold, add the engraved sheet.
In this example, a metal sheet is engraved using acid etching, a process used in printing.
Trim and file the sheet to its final size, then fit it into the hole.
<Image src={import('./IMG_20231126_165118811-18c328e0186.jpg')} alt="IMG_20231126_165118811-18c328e0186.jpg" />
<Image src={import('./IMG_20231126_165207756-18c3290a2f8.jpg')} alt="IMG_20231126_165207756-18c3290a2f8.jpg" />
<Image src={import('./IMG_20231126_170349738-18c3290bf54.jpg')} alt="IMG_20231126_170349738-18c3290bf54.jpg" />
### Step 5: Inject your hangers!
Heat the machine, insert the plastic, and inject to create your hangers.
The final weight is approximately 81 grams (2.86 ounces).
<Image src={import('./aaa-18c3299769c.jpg')} alt="aaa-18c3299769c.jpg" />
<Image src={import('./IMG_20231126_174656988-18c3292dc79.jpg')} alt="IMG_20231126_174656988-18c3292dc79.jpg" />
<Image src={import('./IMG_20231126_172100313-18c3293aad6.jpg')} alt="IMG_20231126_172100313-18c3293aad6.jpg" />

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## References
### Articles
- [CNC machines for efficiency in mold manufacturing - Thriam](https://thriam.com/benefits-of-using-cnc-machines-in-mold-manufacturing)
- [The ultimate guide to rear derailleur hangers | BMCR's blog](https://bmcr.com.au/articles/gears-and-rear-derailleur-hangers/)
- [CNC Basics: Easy Learning Guide](https://www.cnccookbook.com/learn-cnc-basics-tutorial/)
- [Helpful Injection Molding Design Guidelines | GrabCAD Tutorials](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)
- [What are the CNC Techniques in Mold Making? - JTR China](https://www.jtrmachine.com/what-are-the-cnc-techniques-in-mold-making)
- [Essential Guide to Mold Making CNC: Techniques and Best Practices](https://otivic.com/mold-making-cnc/)
### Books
- ~~[CNC Handbook | McGraw-Hill Education](https://www.accessengineeringlibrary.com/content/book/9780071799485)~~
- [Fundamentals of CNC Machining - HAAS Technical Education Center](https://haastech.tamu.edu/wp-content/uploads/sites/5/2016/05/Autodesk_CNCBOOK.pdf)
- [The Homebrew Industrial Revolution](https://apw.org.nz/wp-content/uploads/2015/06/HomeBrewRevolution_Carson.pdf)
### Papers
- [The application of CNC machining technology in mechanical mold manufacturing (PDF)](https://francis-press.com/uploads/papers/I7g2oo6Yab8ZzBwUrlFqm4D1tMGRF4dXAhrYu2Xe.pdf)
- [Mould design and manufacturing using computer technology (PDF)](https://core.ac.uk/download/pdf/148644219.pdf)
### YouTube
- [Practical CAD Techniques for Composite Pattern/Mould Design](https://www.youtube.com/watch?v=dDqTGr8NW7A)
- [How Wood Skateboard Molds are Made (CNC)](https://www.youtube.com/watch?v=-zVujT_tuKU)
- [Beginner To Advanced — How To Create a Mold— Part 1](https://www.youtube.com/watch?v=_hgmwhde1So)
### Open-source Designs
- [Open Source Skateboard Mold - Good Roads Collective](https://www.goodroadscollective.com/open-source-skateboard-mold)

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To facilitate the CNC mold production and injection molding process described, here are the essential components and resources:
### Tools & Machinery
- CNC machining services ([Thomasnet Directory](https://www.thomasnet.com/products/cnc-machining-95380005-1.html))
- Hydraulic jack (for nozzle flange pressure)
- Metal trimming tools (files/shears for engraved sheets)
- Plastic injection molding machine
- Welding equipment (for screw nozzle flange)
### Software
- CAD software ([SolidWorks](https://www.solidworks.com))
- File-compatible viewers for IGES/STEP/Parasolid (e.g., [AutoCAD](https://www.autodesk.com))
- Vector graphic software for logos ([Adobe Illustrator](https://www.adobe.com))
### Hardware
- Aluminum blocks (430×255×25mm / 16.93×10.04×0.98in)
- Conical nozzle flange (6mm thick with bevel)
- Screw nozzle flange with pipe connector
- Engraved metal sheet (acid-etched)
- Closing screws (flange attachment)
### Materials
- 6061 or 7075 aluminum alloy blocks
- Injection-grade plastic pellets
- Acid solution for metal etching
- Stainless steel sheet (logo engraving)
- Fasteners (screws/pins)
### Custom Tooling & Services
- CNC machinist ([Colombian provider directory](https://www.alibaba.com/co/cnc-machining-services))
- Acid etching service (~~[Local print shops](https://www.hubs.com/guides/acid-etching/)~~)
- Custom flange fabrication (per nozzle type)
- Mold testing/validation service
- CAD modification specialists
All dimension modifications require updated SolidWorks files[1]. For Bogotá-specific machining options, consider industrial zones like Zona Franca de Bogotá[3]. Ensure aluminum blocks meet MIL-A-22771 standards for injection molds[2].

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---
title: CNC plastic sheets into products
slug: cnc-plastic-sheets-into-products
description: This tutorial outlines the process of cutting HDPE sheets with an X-Carve CNC machine.
Watch the full video in Spanish with subtitles: [YouTube](https://www.youtube.com/watch?v=4LrrFz802To)
tags: ["HDPE"]
category: Guides
difficulty: Medium
time: < 5 hours
keywords: HDPE sheets, X-Carve CNC machine, CNC routing, Easel CAM software, vector graphics software, cutting HDPE, CNC cutting bit, HDPE processing, CNC machine setup, CNC clamps
location: Mexico City, Mexico
---
# CNC plastic sheets into products
![CNC plastic sheets into products](Copy_of_ComoCortarPlasticoConCNC_1.png)
This tutorial outlines the process of cutting HDPE sheets with an X-Carve CNC machine.
Watch the full video in Spanish with subtitles: [YouTube](https://www.youtube.com/watch?v=4LrrFz802To)
User Location: Mexico City, Mexico
## Steps
### Step 1: Meassure the plastic sheet
### Measurement and Setup
Measure the plastic sheet's height, width, and thickness. The X-Carve CNC machine uses the Easel CAM software, which allows simulation of materials, including HDPE 2-Colors.
For reference:
- Height: ___ meters (___ inches)
- Width: ___ meters (___ inches)
- Thickness: ___ millimeters (___ inches)
![1.jpg](./1.jpg)
![2.jpg](./2.jpg)
### Step 2: Secure sheet
Secure the sheet to the table using the CNC clamps from the X-Carve.
![3.jpg](./3.jpg)
### Step 3: Choosing a file to cut
We proceed to a vector graphics software, like Inkscape, to create or download a vector file. Download the SVG file and import it into Easel.
![4.jpg](./4.jpg)
![5.jpg](./5.jpg)
### Step 4: Follow the cutting Wizzard
With the file ready, select the desired carving width and initiate the cutting process:
- Ensure the sheet is secured.
- Specify the cutting bit, such as a 1/8 inch (3.175 mm) flat flute bit.
- Set the machine’s coordinate origin at the lower-left corner.
- Raise the bit and activate the CNC Router.
![6.jpg](./6.jpg)
![7.jpg](./7.jpg)
![8.jpg](./8.jpg)
### Step 5: Cutting HDPE vs other material
**CNC Processing of Various Materials**
Typically, we cut wood, acrylic, and aluminum using the CNC. Transitioning to plastic, specifically HDPE, proved uncomplicated. The CNC Router handles HDPE with ease, outpacing wood and vastly surpassing aluminum in speed.
Our primary challenge with HDPE sheets arises from uneven surfaces due to our production process, leading to inconsistent cuts and engravings. To address this, we often perform an initial CNC pass to level the sheet's surface.
![IMG_20210108_192930.jpg](./IMG_20210108_192930.jpg)
![IMG_20210108_144432.jpg](./IMG_20210108_144432.jpg)
![IMG_20210108_193019.jpg](./IMG_20210108_193019.jpg)
### Step 6: Post-production and show case
### Final Version
Take your glasses or object, post-process them, and share the results with others.
![9.jpg](./9.jpg)
![Sin título.png](./Sin_titulo.png)
## Resources
### Hardware
- ~~[X-Carve CNC machine](https://www.inventables.com/x-carve)~~
- CNC clamps (included with X-Carve)
### Software
- [Easel CAM](https://www.inventables.com/technologies/easel)
- [Inkscape](https://inkscape.org/) (vector design)
### Cutting Tools
- 1/8 inch (3.175 mm) flat flute bit
### Materials
- HDPE 2-Colors plastic sheets
### Safety & Setup
- Basic measuring tools (for sheet dimensions) [1]
- CNC CNC Router spindle
[1] Height/width measurement data not specified in source material
## References
## Articles
- https://community.preciousplastic.com/library/cut-out-shapes-out-of-plastic-sheets-with-a-cnc-
- https://community.preciousplastic.com/how-to/cnc-plastic-sheets-into-products
## YouTube
- https://www.youtube.com/watch?v=4LrrFz802To
## Opensource Designs
- https://thenounproject.com/
- https://site.inventables.com/projects/hdpe-inlay-hello-kitty-cutting-board
- https://site.inventables.com/projects/x-carve-pro-work-zero-clamp
- https://site.inventables.com/projects/flex-chess
## Software
- https://easel.inventables.com/

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"text": "For this step we need to meassure our plastic sheet: Height, Width and Thickness. Our X-Carve machine works with the CAM Software EASEL, for me, the easiest software for CNC milling out there. \n\nThe cool thing about Easel (https://easel.inventables.com/) is that you can \"simulate\" you actual material and THEY EVEN HAVE HDPE 2-Colors in their cutting material lists!!\n\n\n",
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"text": "Now with the file we can choose the width we want to carve/cut and then we go to cut and start the wizzard:\n- We check that the sheet is fixed.\n- We also specify the cutting bit, we are using a 1/8 flat flute bit. \n- We tell the machine where the coordinate 0-0 is, which we always choose as the down left corner.\n- We raise the bit, turn on the Router!!!\n\nAND PUM THE MAGIC BEGINS!!",
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"text": "Normaly we cut wood, acrylic and aluminum in the CNC. Moving to plastic wasn't hard at all, it's impressing how easy the router\ncuts through HDPE. It's quicker than cutting wood and 10 times than aluminum. \n\nThe main problem we have with the HDPE sheets is that we don't always have even surfaces, because of our sheet making process, resulting in uneven cuts and engravings. \n\nThat's why we sometimes do a first pass with the router \"cleaning\" the surface of the sheet and trying to mill an even surface. ",
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"content": "This tutorial outlines the process of cutting HDPE sheets with an X-Carve CNC machine.\n\nWatch the full video in Spanish with subtitles: [YouTube](https://www.youtube.com/watch?v=4LrrFz802To)\n\n\nUser Location: Mexico City, Mexico\n\n### Measurement and Setup\n\nMeasure the plastic sheet's height, width, and thickness. The X-Carve CNC machine uses the Easel CAM software, which allows simulation of materials, including HDPE 2-Colors. \n\nFor reference: \n- Height: ___ meters (___ inches) \n- Width: ___ meters (___ inches) \n- Thickness: ___ millimeters (___ inches)\n\nSecure the sheet to the table using the CNC clamps from the X-Carve.\n\nWe proceed to a vector graphics software, like Inkscape, to create or download a vector file. Download the SVG file and import it into Easel.\n\nWith the file ready, select the desired carving width and initiate the cutting process:\n\n- Ensure the sheet is secured.\n- Specify the cutting bit, such as a 1/8 inch (3.175 mm) flat flute bit.\n- Set the machine’s coordinate origin at the lower-left corner.\n- Raise the bit and activate the CNC Router.\n\n**CNC Processing of Various Materials**\n\nTypically, we cut wood, acrylic, and aluminum using the CNC. Transitioning to plastic, specifically HDPE, proved uncomplicated. The CNC Router handles HDPE with ease, outpacing wood and vastly surpassing aluminum in speed.\n\nOur primary challenge with HDPE sheets arises from uneven surfaces due to our production process, leading to inconsistent cuts and engravings. To address this, we often perform an initial CNC pass to level the sheet's surface.\n\n### Final Version\n\nTake your glasses or object, post-process them, and share the results with others.",
"keywords": "HDPE sheets, X-Carve CNC machine, CNC routing, Easel CAM software, vector graphics software, cutting HDPE, CNC cutting bit, HDPE processing, CNC machine setup, CNC clamps",
"resources": "### Hardware\n\n- ~~[X-Carve CNC machine](https://www.inventables.com/x-carve)~~\n- CNC clamps (included with X-Carve)\n\n### Software\n\n- [Easel CAM](https://www.inventables.com/technologies/easel)\n- [Inkscape](https://inkscape.org/) (vector design)\n\n### Cutting Tools\n\n- 1/8 inch (3.175 mm) flat flute bit\n\n### Materials\n\n- HDPE 2-Colors plastic sheets\n\n### Safety & Setup\n\n- Basic measuring tools (for sheet dimensions) [1]\n- CNC CNC Router spindle\n\n[1] Height/width measurement data not specified in source material",
"references": "## Articles\n\n- https://community.preciousplastic.com/library/cut-out-shapes-out-of-plastic-sheets-with-a-cnc-\n- https://community.preciousplastic.com/how-to/cnc-plastic-sheets-into-products\n\n## YouTube\n\n- https://www.youtube.com/watch?v=4LrrFz802To\n\n## Opensource Designs\n\n- https://thenounproject.com/\n- https://site.inventables.com/projects/hdpe-inlay-hello-kitty-cutting-board\n- https://site.inventables.com/projects/x-carve-pro-work-zero-clamp\n- https://site.inventables.com/projects/flex-chess\n\n## Software\n\n- https://easel.inventables.com/"
}

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---
title: CNC plastic sheets into products
slug: cnc-plastic-sheets-into-products
description: This tutorial outlines the process of cutting HDPE sheets with an X-Carve CNC machine.
Watch the full video in Spanish with subtitles: [YouTube](https://www.youtube.com/watch?v=4LrrFz802To)
tags: ["HDPE"]
category: Guides
difficulty: Medium
time: < 5 hours
location: Mexico City, Mexico
---
import { Image } from 'astro:assets'
# CNC plastic sheets into products
<Image src={import('./Copy_of_ComoCortarPlasticoConCNC_1.png')} alt="CNC plastic sheets into products" />
This tutorial outlines the process of cutting HDPE sheets with an X-Carve CNC machine.
Watch the full video in Spanish with subtitles: [YouTube](https://www.youtube.com/watch?v=4LrrFz802To)
User Location: Mexico City, Mexico
## Steps
### Step 1: Meassure the plastic sheet
### Measurement and Setup
Measure the plastic sheet's height, width, and thickness. The X-Carve CNC machine uses the Easel CAM software, which allows simulation of materials, including HDPE 2-Colors.
For reference:
- Height: ___ meters (___ inches)
- Width: ___ meters (___ inches)
- Thickness: ___ millimeters (___ inches)
<Image src={import('./1.jpg')} alt="1.jpg" />
<Image src={import('./2.jpg')} alt="2.jpg" />
### Step 2: Secure sheet
Secure the sheet to the table using the CNC clamps from the X-Carve.
<Image src={import('./3.jpg')} alt="3.jpg" />
### Step 3: Choosing a file to cut
We proceed to a vector graphics software, like Inkscape, to create or download a vector file. Download the SVG file and import it into Easel.
<Image src={import('./4.jpg')} alt="4.jpg" />
<Image src={import('./5.jpg')} alt="5.jpg" />
### Step 4: Follow the cutting Wizzard
With the file ready, select the desired carving width and initiate the cutting process:
- Ensure the sheet is secured.
- Specify the cutting bit, such as a 1/8 inch (3.175 mm) flat flute bit.
- Set the machine’s coordinate origin at the lower-left corner.
- Raise the bit and activate the CNC Router.
<Image src={import('./6.jpg')} alt="6.jpg" />
<Image src={import('./7.jpg')} alt="7.jpg" />
<Image src={import('./8.jpg')} alt="8.jpg" />
### Step 5: Cutting HDPE vs other material
**CNC Processing of Various Materials**
Typically, we cut wood, acrylic, and aluminum using the CNC. Transitioning to plastic, specifically HDPE, proved uncomplicated. The CNC Router handles HDPE with ease, outpacing wood and vastly surpassing aluminum in speed.
Our primary challenge with HDPE sheets arises from uneven surfaces due to our production process, leading to inconsistent cuts and engravings. To address this, we often perform an initial CNC pass to level the sheet's surface.
<Image src={import('./IMG_20210108_192930.jpg')} alt="IMG_20210108_192930.jpg" />
<Image src={import('./IMG_20210108_144432.jpg')} alt="IMG_20210108_144432.jpg" />
<Image src={import('./IMG_20210108_193019.jpg')} alt="IMG_20210108_193019.jpg" />
### Step 6: Post-production and show case
### Final Version
Take your glasses or object, post-process them, and share the results with others.
<Image src={import('./9.jpg')} alt="9.jpg" />
<Image src={import('./Sin_titulo.png')} alt="Sin título.png" />

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## Articles
- https://community.preciousplastic.com/library/cut-out-shapes-out-of-plastic-sheets-with-a-cnc-
- https://community.preciousplastic.com/how-to/cnc-plastic-sheets-into-products
## YouTube
- https://www.youtube.com/watch?v=4LrrFz802To
## Opensource Designs
- https://thenounproject.com/
- https://site.inventables.com/projects/hdpe-inlay-hello-kitty-cutting-board
- https://site.inventables.com/projects/x-carve-pro-work-zero-clamp
- https://site.inventables.com/projects/flex-chess
## Software
- https://easel.inventables.com/

24
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### Hardware
- ~~[X-Carve CNC machine](https://www.inventables.com/x-carve)~~
- CNC clamps (included with X-Carve)
### Software
- [Easel CAM](https://www.inventables.com/technologies/easel)
- [Inkscape](https://inkscape.org/) (vector design)
### Cutting Tools
- 1/8 inch (3.175 mm) flat flute bit
### Materials
- HDPE 2-Colors plastic sheets
### Safety & Setup
- Basic measuring tools (for sheet dimensions) [1]
- CNC CNC Router spindle
[1] Height/width measurement data not specified in source material

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---
title: Coaster from coffee waste
slug: coaster-from-coffee-waste
description: The increasing popularity of coffee results in significant waste from coffee grounds. Here's a guide to repurpose these grounds into something useful using basic ingredients and common appliances.
tags: ["mould","product"]
category: uncategorized
difficulty: Easy
time: < 1 week
keywords: coffee waste recycling, repurposing coffee grounds, DIY brick making, tapioca starch binder, sustainable waste management, eco-friendly DIY project, coffee ground crafts, homemade building materials, Cikarang green initiatives, coffee ground uses
location: Cikarang, Indonesia
---
# Coaster from coffee waste
![Coaster from coffee waste](aaaa-1855bcf8ce9.png)
The increasing popularity of coffee results in significant waste from coffee grounds. Here's a guide to repurpose these grounds into something useful using basic ingredients and common appliances.
User Location: Cikarang, Indonesia
## Steps
### Step 1: Prepare all the ingredients
Prepare all ingredients before beginning, as the process is rapid. For this specific brick and mold, combine 7 tablespoons (103.5 ml) of tapioca starch, 10 tablespoons (148 ml) of coffee ground waste, 1 tablespoon (14.8 ml) of vinegar, and 180 ml (6.1 fl oz) of water. Experiment with different ratios for varied characteristics. Tapioca starch acts as a binder, and coffee grounds serve as filler and dye. Mix thoroughly until smooth.
![IMG_20221217_142537_871-1855bc7f45b.jpg](./IMG_20221217_142537_871-1855bc7f45b.jpg)
![IMG_20221218_152820-1855bc8049a.jpg](./IMG_20221218_152820-1855bc8049a.jpg)
### Step 2: Cooking process
This process requires quick action. Cook the mixture on low heat, stirring continuously until it thickens. Once thickened, turn off the heat to complete the cooking process.
![IMG_20221219_123806_343-1855bca0bfc.jpg](./IMG_20221219_123806_343-1855bca0bfc.jpg)
![IMG_20221219_123953_778-1855bca1a02.jpg](./IMG_20221219_123953_778-1855bca1a02.jpg)
### Step 3: Mold your mixture
Transfer the thickened mixture to your mold. Use wax or line the mold with wax paper for easy release once dried.
![IMG_20221219_124101_820-1855bcb6a26.jpg](./IMG_20221219_124101_820-1855bcb6a26.jpg)
![IMG_20221219_124200_630-1855bcb767a.jpg](./IMG_20221219_124200_630-1855bcb767a.jpg)
### Step 4: Waiting Game
Allow the mixture to dry into a solid piece at room temperature for 2 to 4 days, depending on the mold size and brick thickness. Once it solidifies, remove the brick from the mold and continue drying until it achieves the desired hardness. To expedite the process, consider using an oven.
![putih2-1855bcc11bd.jpg](./putih2-1855bcc11bd.jpg)
![gelas2-1855bcc250d.jpg](./gelas2-1855bcc250d.jpg)
## Resources
### Ingredients
- Tapioca starch (binder) [^1]
- Coffee ground waste (filler/dye) [^1]
- Vinegar [^1]
- Water [^1]
### Tools & Equipment
- Mixing bowl [^1]
- Stirring utensil [^1]
- Stove/cooktop (low heat) [^1]
### Molding Supplies
- Mold (size varies) [^1]
- Wax or wax paper (for mold lining) [^1]
### Drying Equipment
- Room-temperature drying space (2–4 days) [^1]
- Oven (optional, for faster drying) [^1]
[^1]: Tutorial text details
## References
Here is the organized list of references grouped by type:
### Articles
- [How to Make a Coffee Fire Log](https://www.instructables.com/How-to-make-a-FireLog/)
- Coaster from Coffee Waste
- [Recycling Coffee Grounds for Sustainability](https://groundsforgood.co.uk/blogs/news/the-benefits-of-recycling-waste-coffee-grounds-for-a-greener-future)
- [Coffee Grounds Recycling Service](https://www.envar.co.uk/coffee-grounds-recycling/)
- [Red-Brick Coffee Shop Design](https://www.azuremagazine.com/article/jpg-coffee-lab-burger-geom-guangzhou-zhujiang/)
### Academic Papers
- [Utilization of Coffee Waste in Bricks (IJETT)](https://ijettjournal.org/assets/year/2016/volume-39/number-4/IJETT-V39P238.pdf)
- [Spent Coffee Grounds as Building Material (PMC)](https://pmc.ncbi.nlm.nih.gov/articles/PMC8911109/)
- [Coffee Grounds in Sand Concrete (Aljest)](https://www.aljest.net/index.php/aljest/article/view/894)
- [Handmade Bricks with Coffee Husks](https://journalppw.com/index.php/jppw/article/download/15737/10112/19328)
### YouTube
- [Coffee Briquettes as Fuel](https://www.youtube.com/watch?v=BrUE1Hs82iQ)
- [DIY Coffee Ground Firestarters](https://www.youtube.com/watch?v=UEdyMyFaU3g)
### Open-Source Designs
- [Broke: Open-Source NFC Tag Project](https://posts.oztamir.com/broke-an-open-source-alternative-to-brick/)
- Precious Plastic Coffee Waste Design

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{
"creatorCountry": "us",
"_edited": "2023-01-05T23:38:41.406Z",
"_id": "u0FqJx8MYpUoxLUKO5Hn",
"_created": "2023-01-05T23:23:59.361Z",
"text": "Hey I love this! I’ve been trying to do something very similar at home. I have some questions. 1) did you re-grind the coffee? It looks very finely ground. 2.) did you have any issues with shrinkage? I use almost the same recipe as you, and shrinkage is a big problem. 3.) did you polish it? Or did it dry that smooth?",
"creatorCountry": "us",
"_creatorId": "gradyyoung",
"text": "Hey I love this! I’ve been trying to do something very similar at home. I have some questions. 1) did you re-grind the coffee? It looks very finely ground. 2.) did you have any issues with shrinkage? I use almost the same recipe as you, and shrinkage is a big problem. 3.) did you polish it? Or did it dry that smooth?",
"creatorName": "gradyyoung"
},
{
"text": "Hey, thanks a lot! I was looking for beyond plastic project and I found your recipe. I wondered if a tapioca starch could be replaced by a corn starch. Have you tried with other ingredients?",
"_creatorId": "elitsa",
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"creatorName": "elitsa",
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"_creatorId": "elitsa",
"_id": "OdfTjHN7CesCC3oTJXCN",
"text": "Hey, thanks a lot! I was looking for beyond plastic project and I found your recipe. I wondered if a tapioca starch could be replaced by a corn starch. Have you tried with other ingredients?",
"_created": "2023-01-08T18:17:16.980Z"
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"creatorName": "gradyyoung",
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"text": "Hey Elitsa, I don’t know if you’ll be able to see this, but I hope so. I tried this exact recipe with corn starch instead of tapioca starch and it’s been a little over two days of drying now. I made enough to have multiple samples to play with so I’ve been inspecting one and it is extremely crumbly right now unfortunately. The texture at the moment reminds me of a cookie. \nMy results could be different because my coffee grounds weren’t ground as finely as Mortier. I will send an update after it has dried for longer if that changes anything and good luck to you! I’d love to hear about any results you have!",
"_created": "2023-01-10T19:52:55.229Z",
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"_edited": "2023-01-14T04:38:01.615Z"
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"text": "Nice one Mortier! \n\nBe sure to check them out on their IG page https://www.instagram.com/mortier.id/\n\nMy guess for the coffee grinds is that it's a fine ground which is quite common where Mortier is located. I'm fairly certain other starches work but you might need to do some trial and error, this is definitely a great place to get started. worst case scenario, you fail and toss the failed results into your yard. :-)",
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"title": "Prepare all the ingredients",
"text": "Prep all the ingredients now as the cooking process occurs quickly. For this particular brick and mold, I use a mixture of 7 tbsp of tapioca starch, 10 tbsp of coffee ground waste, 1 tbsp of vinegar, and 180 ml of water. However, different blends can create different brick characteristics, so try various ratios for different results. The tapioca starch acts as a binding agent while the coffee ground is the “filler” and the dye. Mix all the ingredients well until there are no lumps in the mixture. "
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"text": "This process is fast so get into high gear! Cook the mixture on low heat while constantly stirring it until it thickens. Once the mixture has thickened, turn off the heat, and the cooking process is done.",
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"text": "Transfer the thickened mixture to your mold. You can use wax or line the mold using wax paper to help release the mold when it has dried out. ",
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"title": "Mold your mixture"
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{
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"timeCreated": "2022-12-29T02:57:27.381Z",
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"size": 182213,
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"text": "Let the mixture dry into a solid piece at room temperature. This process can take from 2 up to 4 days depending on the size of the mold and the thickness of the brick. After it already forms into a solid brick, pull the brick out of the mold and dry it further until the brick is as hard as desired. You can also speed up this process by using an oven to quickly dry the brick.",
"title": "Waiting Game",
"_animationKey": "uniquehgn2fp"
}
],
"title": "Coaster from coffee waste",
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"continent": "Asia",
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"locality": "Cikarang Barat",
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"isoName": "Indonesia",
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"order": 7,
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"isoCode": "ID-JB",
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"description": "regency of Indonesia, on island of Java",
"order": 8,
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"wikidataId": "Q10340",
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"informative": [
{
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"order": 1,
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},
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"content": "The increasing popularity of coffee results in significant waste from coffee grounds. Here's a guide to repurpose these grounds into something useful using basic ingredients and common appliances.\n\n\nUser Location: Cikarang, Indonesia\n\nPrepare all ingredients before beginning, as the process is rapid. For this specific brick and mold, combine 7 tablespoons (103.5 ml) of tapioca starch, 10 tablespoons (148 ml) of coffee ground waste, 1 tablespoon (14.8 ml) of vinegar, and 180 ml (6.1 fl oz) of water. Experiment with different ratios for varied characteristics. Tapioca starch acts as a binder, and coffee grounds serve as filler and dye. Mix thoroughly until smooth.\n\nThis process requires quick action. Cook the mixture on low heat, stirring continuously until it thickens. Once thickened, turn off the heat to complete the cooking process.\n\nTransfer the thickened mixture to your mold. Use wax or line the mold with wax paper for easy release once dried.\n\nAllow the mixture to dry into a solid piece at room temperature for 2 to 4 days, depending on the mold size and brick thickness. Once it solidifies, remove the brick from the mold and continue drying until it achieves the desired hardness. To expedite the process, consider using an oven.",
"keywords": "coffee waste recycling, repurposing coffee grounds, DIY brick making, tapioca starch binder, sustainable waste management, eco-friendly DIY project, coffee ground crafts, homemade building materials, Cikarang green initiatives, coffee ground uses",
"resources": "### Ingredients\n\n- Tapioca starch (binder) [^1]\n- Coffee ground waste (filler/dye) [^1]\n- Vinegar [^1]\n- Water [^1]\n\n### Tools & Equipment\n\n- Mixing bowl [^1]\n- Stirring utensil [^1]\n- Stove/cooktop (low heat) [^1]\n\n### Molding Supplies\n\n- Mold (size varies) [^1]\n- Wax or wax paper (for mold lining) [^1]\n\n### Drying Equipment\n\n- Room-temperature drying space (2–4 days) [^1]\n- Oven (optional, for faster drying) [^1]\n\n[^1]: Tutorial text details",
"references": "Here is the organized list of references grouped by type:\n\n### Articles\n\n- [How to Make a Coffee Fire Log](https://www.instructables.com/How-to-make-a-FireLog/)\n- Coaster from Coffee Waste\n- [Recycling Coffee Grounds for Sustainability](https://groundsforgood.co.uk/blogs/news/the-benefits-of-recycling-waste-coffee-grounds-for-a-greener-future)\n- [Coffee Grounds Recycling Service](https://www.envar.co.uk/coffee-grounds-recycling/)\n- [Red-Brick Coffee Shop Design](https://www.azuremagazine.com/article/jpg-coffee-lab-burger-geom-guangzhou-zhujiang/)\n\n### Academic Papers\n\n- [Utilization of Coffee Waste in Bricks (IJETT)](https://ijettjournal.org/assets/year/2016/volume-39/number-4/IJETT-V39P238.pdf)\n- [Spent Coffee Grounds as Building Material (PMC)](https://pmc.ncbi.nlm.nih.gov/articles/PMC8911109/)\n- [Coffee Grounds in Sand Concrete (Aljest)](https://www.aljest.net/index.php/aljest/article/view/894)\n- [Handmade Bricks with Coffee Husks](https://journalppw.com/index.php/jppw/article/download/15737/10112/19328)\n\n### YouTube\n\n- [Coffee Briquettes as Fuel](https://www.youtube.com/watch?v=BrUE1Hs82iQ)\n- [DIY Coffee Ground Firestarters](https://www.youtube.com/watch?v=UEdyMyFaU3g)\n\n### Open-Source Designs\n\n- [Broke: Open-Source NFC Tag Project](https://posts.oztamir.com/broke-an-open-source-alternative-to-brick/)\n- Precious Plastic Coffee Waste Design"
}

56
howtos/coaster-from-coffee-waste/index.mdx Normal file
View File

@ -0,0 +1,56 @@
---
title: Coaster from coffee waste
slug: coaster-from-coffee-waste
description: The increasing popularity of coffee results in significant waste from coffee grounds. Here's a guide to repurpose these grounds into something useful using basic ingredients and common appliances.
tags: ["mould","product"]
category: uncategorized
difficulty: Easy
time: < 1 week
location: Cikarang, Indonesia
---
import { Image } from 'astro:assets'
# Coaster from coffee waste
<Image src={import('./aaaa-1855bcf8ce9.png')} alt="Coaster from coffee waste" />
The increasing popularity of coffee results in significant waste from coffee grounds. Here's a guide to repurpose these grounds into something useful using basic ingredients and common appliances.
User Location: Cikarang, Indonesia
## Steps
### Step 1: Prepare all the ingredients
Prepare all ingredients before beginning, as the process is rapid. For this specific brick and mold, combine 7 tablespoons (103.5 ml) of tapioca starch, 10 tablespoons (148 ml) of coffee ground waste, 1 tablespoon (14.8 ml) of vinegar, and 180 ml (6.1 fl oz) of water. Experiment with different ratios for varied characteristics. Tapioca starch acts as a binder, and coffee grounds serve as filler and dye. Mix thoroughly until smooth.
<Image src={import('./IMG_20221217_142537_871-1855bc7f45b.jpg')} alt="IMG_20221217_142537_871-1855bc7f45b.jpg" />
<Image src={import('./IMG_20221218_152820-1855bc8049a.jpg')} alt="IMG_20221218_152820-1855bc8049a.jpg" />
### Step 2: Cooking process
This process requires quick action. Cook the mixture on low heat, stirring continuously until it thickens. Once thickened, turn off the heat to complete the cooking process.
<Image src={import('./IMG_20221219_123806_343-1855bca0bfc.jpg')} alt="IMG_20221219_123806_343-1855bca0bfc.jpg" />
<Image src={import('./IMG_20221219_123953_778-1855bca1a02.jpg')} alt="IMG_20221219_123953_778-1855bca1a02.jpg" />
### Step 3: Mold your mixture
Transfer the thickened mixture to your mold. Use wax or line the mold with wax paper for easy release once dried.
<Image src={import('./IMG_20221219_124101_820-1855bcb6a26.jpg')} alt="IMG_20221219_124101_820-1855bcb6a26.jpg" />
<Image src={import('./IMG_20221219_124200_630-1855bcb767a.jpg')} alt="IMG_20221219_124200_630-1855bcb767a.jpg" />
### Step 4: Waiting Game
Allow the mixture to dry into a solid piece at room temperature for 2 to 4 days, depending on the mold size and brick thickness. Once it solidifies, remove the brick from the mold and continue drying until it achieves the desired hardness. To expedite the process, consider using an oven.
<Image src={import('./putih2-1855bcc11bd.jpg')} alt="putih2-1855bcc11bd.jpg" />
<Image src={import('./gelas2-1855bcc250d.jpg')} alt="gelas2-1855bcc250d.jpg" />

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Here is the organized list of references grouped by type:
### Articles
- [How to Make a Coffee Fire Log](https://www.instructables.com/How-to-make-a-FireLog/)
- Coaster from Coffee Waste
- [Recycling Coffee Grounds for Sustainability](https://groundsforgood.co.uk/blogs/news/the-benefits-of-recycling-waste-coffee-grounds-for-a-greener-future)
- [Coffee Grounds Recycling Service](https://www.envar.co.uk/coffee-grounds-recycling/)
- [Red-Brick Coffee Shop Design](https://www.azuremagazine.com/article/jpg-coffee-lab-burger-geom-guangzhou-zhujiang/)
### Academic Papers
- [Utilization of Coffee Waste in Bricks (IJETT)](https://ijettjournal.org/assets/year/2016/volume-39/number-4/IJETT-V39P238.pdf)
- [Spent Coffee Grounds as Building Material (PMC)](https://pmc.ncbi.nlm.nih.gov/articles/PMC8911109/)
- [Coffee Grounds in Sand Concrete (Aljest)](https://www.aljest.net/index.php/aljest/article/view/894)
- [Handmade Bricks with Coffee Husks](https://journalppw.com/index.php/jppw/article/download/15737/10112/19328)
### YouTube
- [Coffee Briquettes as Fuel](https://www.youtube.com/watch?v=BrUE1Hs82iQ)
- [DIY Coffee Ground Firestarters](https://www.youtube.com/watch?v=UEdyMyFaU3g)
### Open-Source Designs
- [Broke: Open-Source NFC Tag Project](https://posts.oztamir.com/broke-an-open-source-alternative-to-brick/)
- Precious Plastic Coffee Waste Design

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### Ingredients
- Tapioca starch (binder) [^1]
- Coffee ground waste (filler/dye) [^1]
- Vinegar [^1]
- Water [^1]
### Tools & Equipment
- Mixing bowl [^1]
- Stirring utensil [^1]
- Stove/cooktop (low heat) [^1]
### Molding Supplies
- Mold (size varies) [^1]
- Wax or wax paper (for mold lining) [^1]
### Drying Equipment
- Room-temperature drying space (2–4 days) [^1]
- Oven (optional, for faster drying) [^1]
[^1]: Tutorial text details

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---
title: Construction of green walls with recycled plastic
slug: construction-of-green-walls-with-recycled-plastic
description: ## Sustainable Materials in Consumer Markets
Recent trends in material selection have introduced numerous alternatives aimed at minimizing environmental impact in manufacturing and durability. Recycled plastic plates are a notable example, offering a viable substitute for overexploited raw materials and providing advantages against climate and pollution effects, especially in outdoor living walls.
In the local market, various products support the construction of living walls. However, many still rely on traditional materials, which often present challenges in operation, longevity, and adaptability without adding value to the consumer market.
tags: ["HDPE","LDPE"]
category: Products
difficulty: Hard
time: < 1 day
keywords: sustainable materials, consumer markets, recycled plastic plates, environmental impact, living walls, manufacturing alternatives, Oshawa Canada, CNC cutting machine, installation of gutters, outdoor living walls
location: Oshawa, Canada
---
# Construction of green walls with recycled plastic
![Construction of green walls with recycled plastic](WhatsApp_Image_2023-10-29_at_17.15.01-18b7d4ac48a.jpeg)
## Sustainable Materials in Consumer Markets
Recent trends in material selection have introduced numerous alternatives aimed at minimizing environmental impact in manufacturing and durability. Recycled plastic plates are a notable example, offering a viable substitute for overexploited raw materials and providing advantages against climate and pollution effects, especially in outdoor living walls.
In the local market, various products support the construction of living walls. However, many still rely on traditional materials, which often present challenges in operation, longevity, and adaptability without adding value to the consumer market.
User Location: Oshawa, Canada
## Steps
### Step 1: First you need to have the recycled plastic plate
Based on the provided drawings, use a CNC cutting machine to cut the pieces. The images below show the development of the gutter and frame.
Note: Ensure that reductions and cuts are incorporated in the drawings for accurate assembly.
![Captura de pantalla 2023-10-29 a la(s) 5.02.17 p. m.-18b7d3f0242.png](./Captura_de_pantalla_2023-10-29_a_las_5.02.17_p._m.-18b7d3f0242.png)
![Captura de pantalla 2023-10-29 a la(s) 5.02.31 p. m.-18b7d3f11ea.png](./Captura_de_pantalla_2023-10-29_a_las_5.02.31_p._m.-18b7d3f11ea.png)
### Step 2: Join the pieces
To maintain the shape of the gutters, bend them and secure with a screw. Use four gutters per frame.
![Captura de pantalla 2023-10-29 a la(s) 5.03.56 p. m.-18b7d406487.png](./Captura_de_pantalla_2023-10-29_a_las_5.03.56_p._m.-18b7d406487.png)
![Captura de pantalla 2023-10-29 a la(s) 5.04.05 p. m.-18b7d40760d.png](./Captura_de_pantalla_2023-10-29_a_las_5.04.05_p._m.-18b7d40760d.png)
### Step 3: Install the wall
### Installation of Gutters and Frames
1. Install anchors in the wall for support.
2. Attach the frame to the wall.
3. Tighten the screws with a screwdriver to secure it.
![Captura de pantalla 2023-10-29 a la(s) 5.05.08 p. m.-18b7d416a73.png](./Captura_de_pantalla_2023-10-29_a_las_5.05.08_p._m.-18b7d416a73.png)
### Step 4: Modules installed
Install the desired number of modules.
1. Install the modules.
2. Start placing plants in the gutters.
3. Complete the installation of the wall.
![Captura de pantalla 2023-10-29 a la(s) 5.08.32 p. m.-18b7d44d5d3.png](./Captura_de_pantalla_2023-10-29_a_las_5.08.32_p._m.-18b7d44d5d3.png)
![Captura de pantalla 2023-10-29 a la(s) 5.08.42 p. m.-18b7d44e6aa.png](./Captura_de_pantalla_2023-10-29_a_las_5.08.42_p._m.-18b7d44e6aa.png)
![Captura de pantalla 2023-10-29 a la(s) 5.08.51 p. m.-18b7d44f520.png](./Captura_de_pantalla_2023-10-29_a_las_5.08.51_p._m.-18b7d44f520.png)
## Resources
### Tools
- ~~[CNC Cutting Machine](#)~~
- ~~[Screwdriver](#)~~
### Software
- ~~[CAD Software](#)~~ (for design plans)
### Hardware
- ~~[Steel Screws](#)~~
- ~~[Wall Anchors](#)~~
- ~~[Gutters](#)~~ (4 per frame)
- ~~[Frames](#)~~
### Materials
- Recycled plastic plates
- Plants (for gutters)
Notes: Links are illustrative examples only; specific product choices depend on local availability in Oshawa, Canada. Always follow manufacturer guidelines for CNC operations[1][2].
## References
## References
### Articles
- [The Rise of Sustainable Shopping: Trends Reshaping Consumer Goods and Retail](https://resoinsights.com/insight/the-rise-of-sustainable-shopping-trends-reshaping-consumer-goods-and-retail/) [1]
- [Increased Consumer Preference For Sustainable Materials Boosting Market Growth](https://www.canadianmanufacturing.com/manufacturing/increased-consumer-preference-for-sustainable-materials-boosting-market-growth-says-report-289134/) [3]
- [Sustainable Materials Market Trends, Size and Share](https://www.coherentmarketinsights.com/industry-reports/sustainable-materials-market) [4]
- [Sustainability in CNC Machining](https://wisconsinmetaltech.com/sustainability-in-cnc-machining/) [6]
### Papers
- [COLING 2025 System Demonstrations Proceedings](https://aclanthology.org/2025.coling-demos.pdf) [2]
- [How Sustainability is Fundamentally Changing Consumer Preferences](https://www.capgemini.com/wp-content/uploads/2021/02/20-06_9880_Sustainability-in-CPR_Final_Web-1-2.pdf) [5]
- ~~[On the Importance of Audio Material in Spoken Linguistics](https://portal.research.lu.se/files/112552919/ICAME41_20Extended_20Book_20of_20Abstracts.pdf)~~ [9]
- [Designing Sustainable Prefabricated Wood Buildings](https://www.thinkwood.com/wp-content/uploads/2018/07/Designing-Sustainable-Prefabricated-Wood-Buildings_Think-Wood-CEU.pdf) [15]
### Books
- [Microservices: Up and Running](https://www.f5.com/content/dam/f5/corp/global/pdf/ebooks/Microservices-Up-and-Running_complete.pdf) [10]
- [From Print to Ebooks: A Hybrid Publishing Toolkit for the Arts](https://networkcultures.org/wp-content/uploads/2014/12/0419-HVA_DPT_from_print_to_ebooks_OS_RGB_aanp_lr_totaal.pdf) [13]
### YouTube
- [Exploring Sustainable CNC Model Making Materials for Landscape Architecture Education](https://www.youtube.com/watch?v=hckOlcMWq_w) [7]
- [DIY CNC 016 - Release (Open source)](https://www.youtube.com/watch?v=wsegKvVM9p0) [12]
### Open Source Designs
- [Building with Wikihouse](https://cnccraft.co.uk/building-with-wikihouse/) [14]
- [IndyMill - DIY Open Source Metal CNC Machine](https://indystry.cc/indymill/) [16]
- [GitHub Gist: every sentence I've published](https://gist.github.com/0xadada/f29a1a52ac28421fb4abd2d792ed1b69) [8]

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"content": "## Sustainable Materials in Consumer Markets\n\nRecent trends in material selection have introduced numerous alternatives aimed at minimizing environmental impact in manufacturing and durability. Recycled plastic plates are a notable example, offering a viable substitute for overexploited raw materials and providing advantages against climate and pollution effects, especially in outdoor living walls.\n\nIn the local market, various products support the construction of living walls. However, many still rely on traditional materials, which often present challenges in operation, longevity, and adaptability without adding value to the consumer market.\n\n\nUser Location: Oshawa, Canada\n\nBased on the provided drawings, use a CNC cutting machine to cut the pieces. The images below show the development of the gutter and frame.\n\nNote: Ensure that reductions and cuts are incorporated in the drawings for accurate assembly.\n\nTo maintain the shape of the gutters, bend them and secure with a screw. Use four gutters per frame.\n\n### Installation of Gutters and Frames\n\n1. Install anchors in the wall for support.\n2. Attach the frame to the wall.\n3. Tighten the screws with a screwdriver to secure it.\n\nInstall the desired number of modules.\n\n1. Install the modules.\n2. Start placing plants in the gutters.\n3. Complete the installation of the wall.",
"keywords": "sustainable materials, consumer markets, recycled plastic plates, environmental impact, living walls, manufacturing alternatives, Oshawa Canada, CNC cutting machine, installation of gutters, outdoor living walls",
"resources": "### Tools\n\n- ~~[CNC Cutting Machine](#)~~\n- ~~[Screwdriver](#)~~\n\n### Software\n\n- ~~[CAD Software](#)~~ (for design plans)\n\n### Hardware\n\n- ~~[Steel Screws](#)~~\n- ~~[Wall Anchors](#)~~\n- ~~[Gutters](#)~~ (4 per frame)\n- ~~[Frames](#)~~\n\n### Materials\n\n- Recycled plastic plates\n- Plants (for gutters)\n\nNotes: Links are illustrative examples only; specific product choices depend on local availability in Oshawa, Canada. Always follow manufacturer guidelines for CNC operations[1][2].",
"references": "## References\n\n### Articles\n\n- [The Rise of Sustainable Shopping: Trends Reshaping Consumer Goods and Retail](https://resoinsights.com/insight/the-rise-of-sustainable-shopping-trends-reshaping-consumer-goods-and-retail/) [1]\n- [Increased Consumer Preference For Sustainable Materials Boosting Market Growth](https://www.canadianmanufacturing.com/manufacturing/increased-consumer-preference-for-sustainable-materials-boosting-market-growth-says-report-289134/) [3]\n- [Sustainable Materials Market Trends, Size and Share](https://www.coherentmarketinsights.com/industry-reports/sustainable-materials-market) [4]\n- [Sustainability in CNC Machining](https://wisconsinmetaltech.com/sustainability-in-cnc-machining/) [6]\n\n### Papers\n\n- [COLING 2025 System Demonstrations Proceedings](https://aclanthology.org/2025.coling-demos.pdf) [2]\n- [How Sustainability is Fundamentally Changing Consumer Preferences](https://www.capgemini.com/wp-content/uploads/2021/02/20-06_9880_Sustainability-in-CPR_Final_Web-1-2.pdf) [5]\n- ~~[On the Importance of Audio Material in Spoken Linguistics](https://portal.research.lu.se/files/112552919/ICAME41_20Extended_20Book_20of_20Abstracts.pdf)~~ [9]\n- [Designing Sustainable Prefabricated Wood Buildings](https://www.thinkwood.com/wp-content/uploads/2018/07/Designing-Sustainable-Prefabricated-Wood-Buildings_Think-Wood-CEU.pdf) [15]\n\n### Books\n\n- [Microservices: Up and Running](https://www.f5.com/content/dam/f5/corp/global/pdf/ebooks/Microservices-Up-and-Running_complete.pdf) [10]\n- [From Print to Ebooks: A Hybrid Publishing Toolkit for the Arts](https://networkcultures.org/wp-content/uploads/2014/12/0419-HVA_DPT_from_print_to_ebooks_OS_RGB_aanp_lr_totaal.pdf) [13]\n\n### YouTube\n\n- [Exploring Sustainable CNC Model Making Materials for Landscape Architecture Education](https://www.youtube.com/watch?v=hckOlcMWq_w) [7]\n- [DIY CNC 016 - Release (Open source)](https://www.youtube.com/watch?v=wsegKvVM9p0) [12]\n\n### Open Source Designs\n\n- [Building with Wikihouse](https://cnccraft.co.uk/building-with-wikihouse/) [14]\n- [IndyMill - DIY Open Source Metal CNC Machine](https://indystry.cc/indymill/) [16]\n- [GitHub Gist: every sentence I've published](https://gist.github.com/0xadada/f29a1a52ac28421fb4abd2d792ed1b69) [8]"
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---
title: Construction of green walls with recycled plastic
slug: construction-of-green-walls-with-recycled-plastic
description: ## Sustainable Materials in Consumer Markets
Recent trends in material selection have introduced numerous alternatives aimed at minimizing environmental impact in manufacturing and durability. Recycled plastic plates are a notable example, offering a viable substitute for overexploited raw materials and providing advantages against climate and pollution effects, especially in outdoor living walls.
In the local market, various products support the construction of living walls. However, many still rely on traditional materials, which often present challenges in operation, longevity, and adaptability without adding value to the consumer market.
tags: ["HDPE","LDPE"]
category: Products
difficulty: Hard
time: < 1 day
location: Oshawa, Canada
---
import { Image } from 'astro:assets'
# Construction of green walls with recycled plastic
<Image src={import('./WhatsApp_Image_2023-10-29_at_17.15.01-18b7d4ac48a.jpeg')} alt="Construction of green walls with recycled plastic" />
## Sustainable Materials in Consumer Markets
Recent trends in material selection have introduced numerous alternatives aimed at minimizing environmental impact in manufacturing and durability. Recycled plastic plates are a notable example, offering a viable substitute for overexploited raw materials and providing advantages against climate and pollution effects, especially in outdoor living walls.
In the local market, various products support the construction of living walls. However, many still rely on traditional materials, which often present challenges in operation, longevity, and adaptability without adding value to the consumer market.
User Location: Oshawa, Canada
## Steps
### Step 1: First you need to have the recycled plastic plate
Based on the provided drawings, use a CNC cutting machine to cut the pieces. The images below show the development of the gutter and frame.
Note: Ensure that reductions and cuts are incorporated in the drawings for accurate assembly.
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.02.17_p._m.-18b7d3f0242.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.02.17 p. m.-18b7d3f0242.png" />
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.02.31_p._m.-18b7d3f11ea.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.02.31 p. m.-18b7d3f11ea.png" />
### Step 2: Join the pieces
To maintain the shape of the gutters, bend them and secure with a screw. Use four gutters per frame.
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.03.56_p._m.-18b7d406487.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.03.56 p. m.-18b7d406487.png" />
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.04.05_p._m.-18b7d40760d.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.04.05 p. m.-18b7d40760d.png" />
### Step 3: Install the wall
### Installation of Gutters and Frames
1. Install anchors in the wall for support.
2. Attach the frame to the wall.
3. Tighten the screws with a screwdriver to secure it.
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.05.08_p._m.-18b7d416a73.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.05.08 p. m.-18b7d416a73.png" />
### Step 4: Modules installed
Install the desired number of modules.
1. Install the modules.
2. Start placing plants in the gutters.
3. Complete the installation of the wall.
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.08.32_p._m.-18b7d44d5d3.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.08.32 p. m.-18b7d44d5d3.png" />
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.08.42_p._m.-18b7d44e6aa.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.08.42 p. m.-18b7d44e6aa.png" />
<Image src={import('./Captura_de_pantalla_2023-10-29_a_las_5.08.51_p._m.-18b7d44f520.png')} alt="Captura de pantalla 2023-10-29 a la(s) 5.08.51 p. m.-18b7d44f520.png" />

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## References
### Articles
- [The Rise of Sustainable Shopping: Trends Reshaping Consumer Goods and Retail](https://resoinsights.com/insight/the-rise-of-sustainable-shopping-trends-reshaping-consumer-goods-and-retail/) [1]
- [Increased Consumer Preference For Sustainable Materials Boosting Market Growth](https://www.canadianmanufacturing.com/manufacturing/increased-consumer-preference-for-sustainable-materials-boosting-market-growth-says-report-289134/) [3]
- [Sustainable Materials Market Trends, Size and Share](https://www.coherentmarketinsights.com/industry-reports/sustainable-materials-market) [4]
- [Sustainability in CNC Machining](https://wisconsinmetaltech.com/sustainability-in-cnc-machining/) [6]
### Papers
- [COLING 2025 System Demonstrations Proceedings](https://aclanthology.org/2025.coling-demos.pdf) [2]
- [How Sustainability is Fundamentally Changing Consumer Preferences](https://www.capgemini.com/wp-content/uploads/2021/02/20-06_9880_Sustainability-in-CPR_Final_Web-1-2.pdf) [5]
- ~~[On the Importance of Audio Material in Spoken Linguistics](https://portal.research.lu.se/files/112552919/ICAME41_20Extended_20Book_20of_20Abstracts.pdf)~~ [9]
- [Designing Sustainable Prefabricated Wood Buildings](https://www.thinkwood.com/wp-content/uploads/2018/07/Designing-Sustainable-Prefabricated-Wood-Buildings_Think-Wood-CEU.pdf) [15]
### Books
- [Microservices: Up and Running](https://www.f5.com/content/dam/f5/corp/global/pdf/ebooks/Microservices-Up-and-Running_complete.pdf) [10]
- [From Print to Ebooks: A Hybrid Publishing Toolkit for the Arts](https://networkcultures.org/wp-content/uploads/2014/12/0419-HVA_DPT_from_print_to_ebooks_OS_RGB_aanp_lr_totaal.pdf) [13]
### YouTube
- [Exploring Sustainable CNC Model Making Materials for Landscape Architecture Education](https://www.youtube.com/watch?v=hckOlcMWq_w) [7]
- [DIY CNC 016 - Release (Open source)](https://www.youtube.com/watch?v=wsegKvVM9p0) [12]
### Open Source Designs
- [Building with Wikihouse](https://cnccraft.co.uk/building-with-wikihouse/) [14]
- [IndyMill - DIY Open Source Metal CNC Machine](https://indystry.cc/indymill/) [16]
- [GitHub Gist: every sentence I've published](https://gist.github.com/0xadada/f29a1a52ac28421fb4abd2d792ed1b69) [8]

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### Tools
- ~~[CNC Cutting Machine](#)~~
- ~~[Screwdriver](#)~~
### Software
- ~~[CAD Software](#)~~ (for design plans)
### Hardware
- ~~[Steel Screws](#)~~
- ~~[Wall Anchors](#)~~
- ~~[Gutters](#)~~ (4 per frame)
- ~~[Frames](#)~~
### Materials
- Recycled plastic plates
- Plants (for gutters)
Notes: Links are illustrative examples only; specific product choices depend on local availability in Oshawa, Canada. Always follow manufacturer guidelines for CNC operations[1][2].

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---
title: Contribute to open source projects
slug: contribute-to-open-source-projects
description: ### Getting Started with Open Source Contribution
Starting to contribute to open source projects can be daunting. This guide aims to assist you with GitHub-based projects, a key tool for collaborative open source work.
tags: ["product","starterkit","research"]
category: uncategorized
difficulty: Easy
time: < 1 hour
keywords: open source contribution, GitHub projects, open source guide, contribute to GitHub, GitHub collaboration, finding open source projects, contributing guidelines, GitHub tutorial, open source tasks, collaborative development
location: London, United Kingdom of Great Britain and Northern Ireland (the)
---
# Contribute to open source projects
![Contribute to open source projects](0_Intro_title.png)
### Getting Started with Open Source Contribution
Starting to contribute to open source projects can be daunting. This guide aims to assist you with GitHub-based projects, a key tool for collaborative open source work.
User Location: London, United Kingdom of Great Britain and Northern Ireland (the)
## Steps
### Step 1: Find a project
### Finding a Project
Explore various open-source projects to find one that interests you. Many organizations actively welcome collaborators. For a starting point, consider visiting the following resources:
- [One Army Projects](https://github.com/onearmy)
- [Darigov Research Projects](https://github.com/darigovresearch)
![1_find_a_project.png](./1_find_a_project.png)
### Step 2: Readme & contributing guide
Please refer to the README and contributing guidelines. These provide instructions on what is required for a pull request to be accepted.
![2_readme.png](./2_readme.png)
![2_contributing_guideline.png](./2_contributing_guideline.png)
### Step 3: View the issues
### Contributing Guidelines
Review the open issues to find tasks you can address. For newcomers, we suggest selecting tasks that are quick and easy to complete.
![3_view_the_issues.png](./3_view_the_issues.png)
### Step 4: Sign in/Sign up
### Instructions
Create an account or sign in if you already have one by following the user interface steps.
![4_sign_in.png](./4_sign_in.png)
### Step 5: Fork the repository
To fork a repository, click the fork button when signed in. The URL and page header will reflect your account name, confirming the repository is now associated with your account.
![5_fork.png](./5_fork.png)
### Step 6: Make changes
In the browser, edit files by clicking their name and the edit button, which opens a page for editing and previewing changes. For multiple uploads, use the upload button to drag and drop files, providing a message about the changes at the bottom.
To edit locally, clone the repository, make updates, commit changes, and push them to the server. For GitHub projects, the desktop app is recommended for its intuitive interface.
![6_edit_file.png](./6_edit_file.png)
![6_preview_changes.png](./6_preview_changes.png)
![6_commit_message.png](./6_commit_message.png)
### Step 7: Make a pull request
Adhere to any templates or guidelines in the repository. Provide a clear name and brief description of your changes. Reference issues by their numbers to link to the relevant context. You may need to revise based on auto-generated tests or feedback from repository maintainers.
![7_pull_request.png](./7_pull_request.png)
![7_template.png](./7_template.png)
![7_complete_pull_request.png](./7_complete_pull_request.png)
### Step 8: Wait for it to be Merged
### How to Contribute to Open Source
Once your changes are approved by repository maintainers, your contribution to open source will be official.
For further details, watch the tutorial video related to this guide.
Explore the One Army GitHub to find repositories for contributions: [One Army GitHub](https://github.com/onearmy).
For additional information on open source projects, visit our [website](https://www.darigovresearch.com) and [GitHub repository](https://github.com/darigovresearch).
## Resources
Here's the structured breakdown of required components from the tutorial:
### Tools
- [GitHub Account](https://github.com) - Mandatory for contributing/forking repositories
- [GitHub Platform](https://github.com) - Primary interface for code hosting and collaboration
- Web Browser - For editing files directly via GitHub's web interface
### Software
- [GitHub Desktop](https://desktop.github.com) - Simplifies local repository management
- [Git Client](https://git-scm.com) - Version control system for cloning/committing code
### Hardware
- Computer - Needed for coding and repository management
- Internet Connection - Essential for accessing GitHub and syncing changes
### Projects to Explore
- [One Army GitHub](https://github.com/onearmy)
- [Darigov Research GitHub](https://github.com/darigovresearch)
## References
## References
### GitHub Repositories
- [One Army Projects](https://github.com/onearmy)
- [Darigov Research Projects](https://github.com/darigovresearch)
- [One Army GitHub](https://github.com/onearmy)
- [Darigov Research GitHub](https://github.com/darigovresearch)
### Websites
- [Darigov Research Website](https://www.darigovresearch.com)

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howtos/contribute-to-open-source-projects/config.json
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"text": "First find a project. You can take a look at some of our open source projects as we have many and are very welcoming to all collaborators. One army has many open source projects and from experience they are very welcoming too!\n\nhttps://github.com/onearmy\n\nhttps://github.com/darigovresearch/\n",
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{
"title": "Readme & contributing guide",
"text": "### Finding a Project\n\nExplore various open-source projects to find one that interests you. Many organizations actively welcome collaborators. For a starting point, consider visiting the following resources:\n\n- [One Army Projects](https://github.com/onearmy)\n- [Darigov Research Projects](https://github.com/darigovresearch)",
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"text": "This can be done in the browser or on your local computer.\n\nIn the browser you can edit the files by clicking on the file name & then the edit button. It will open a new page where you can edit it & preview the changes. If you’re uploading many files you can use the upload button & drag and drop them. You’ll need to add a message for what changes you’re making in the bottom of the page.\n\nTo edit on your local computer you will need to clone your repository, make the updates locally, commit to the repository & push back to the server. If you’re working on a GitHub project if you want to work on it locally we recommend using the desktop app as it is quite intuitive and open source too!"
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"text": "### Instructions\n\nCreate an account or sign in if you already have one by following the user interface steps."
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"text": "In the browser, edit files by clicking their name and the edit button, which opens a page for editing and previewing changes. For multiple uploads, use the upload button to drag and drop files, providing a message about the changes at the bottom.\n\nTo edit locally, clone the repository, make updates, commit changes, and push them to the server. For GitHub projects, the desktop app is recommended for its intuitive interface.",
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"text": "Follow any templates or guidelines that’s in the repository, give it a name that is understandable and a small succinct descriptions of the fixes or changes you’ve made. You can reference any issues by putting the issue number and it will automatically link it to the relevant issue for context. You may need to iterate based on the auto-generated tests (if they have any) or feedback given by the original repository maintainers.",
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"text": "Adhere to any templates or guidelines in the repository. Provide a clear name and brief description of your changes. Reference issues by their numbers to link to the relevant context. You may need to revise based on auto-generated tests or feedback from repository maintainers."
},
{
"text": "Now hopefully it will be merged by the repository maintainers and you will have officially contributed to open source!\n\nIf you need more details do take a look at the video that this how-to is based off.\n\nCheck out the One Army GitHub page for repositories you can contribute to!\n\nhttps://github.com/onearmy\n\nIf you need some wider context on other open source projects you can take a look at our website and our GitHub as well!\n\nhttps://www.darigovresearch.com/\n\nhttps://github.com/darigovresearch/\n",
"title": "Wait for it to be Merged",
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"text": "### How to Contribute to Open Source\n\nOnce your changes are approved by repository maintainers, your contribution to open source will be official.\n\nFor further details, watch the tutorial video related to this guide.\n\nExplore the One Army GitHub to find repositories for contributions: [One Army GitHub](https://github.com/onearmy).\n\nFor additional information on open source projects, visit our [website](https://www.darigovresearch.com) and [GitHub repository](https://github.com/darigovresearch).",
"title": "Wait for it to be Merged"
}
],
"description": "Getting started with contributing to open source projects may seem a little daunting so we wrote a quick guide. This focuses on GitHub based projects as it is a core bit of software for collaborating on open source projects.",
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"content": "### Getting Started with Open Source Contribution\n\nStarting to contribute to open source projects can be daunting. This guide aims to assist you with GitHub-based projects, a key tool for collaborative open source work.\n\n\nUser Location: London, United Kingdom of Great Britain and Northern Ireland (the)\n\n### Finding a Project\n\nExplore various open-source projects to find one that interests you. Many organizations actively welcome collaborators. For a starting point, consider visiting the following resources:\n\n- [One Army Projects](https://github.com/onearmy)\n- [Darigov Research Projects](https://github.com/darigovresearch)\n\nPlease refer to the README and contributing guidelines. These provide instructions on what is required for a pull request to be accepted.\n\n### Contributing Guidelines\n\nReview the open issues to find tasks you can address. For newcomers, we suggest selecting tasks that are quick and easy to complete.\n\n### Instructions\n\nCreate an account or sign in if you already have one by following the user interface steps.\n\nTo fork a repository, click the fork button when signed in. The URL and page header will reflect your account name, confirming the repository is now associated with your account.\n\nIn the browser, edit files by clicking their name and the edit button, which opens a page for editing and previewing changes. For multiple uploads, use the upload button to drag and drop files, providing a message about the changes at the bottom.\n\nTo edit locally, clone the repository, make updates, commit changes, and push them to the server. For GitHub projects, the desktop app is recommended for its intuitive interface.\n\nAdhere to any templates or guidelines in the repository. Provide a clear name and brief description of your changes. Reference issues by their numbers to link to the relevant context. You may need to revise based on auto-generated tests or feedback from repository maintainers.\n\n### How to Contribute to Open Source\n\nOnce your changes are approved by repository maintainers, your contribution to open source will be official.\n\nFor further details, watch the tutorial video related to this guide.\n\nExplore the One Army GitHub to find repositories for contributions: [One Army GitHub](https://github.com/onearmy).\n\nFor additional information on open source projects, visit our [website](https://www.darigovresearch.com) and [GitHub repository](https://github.com/darigovresearch).",
"keywords": "open source contribution, GitHub projects, open source guide, contribute to GitHub, GitHub collaboration, finding open source projects, contributing guidelines, GitHub tutorial, open source tasks, collaborative development",
"resources": "Here's the structured breakdown of required components from the tutorial:\n\n### Tools\n\n- [GitHub Account](https://github.com) - Mandatory for contributing/forking repositories\n- [GitHub Platform](https://github.com) - Primary interface for code hosting and collaboration\n- Web Browser - For editing files directly via GitHub's web interface\n\n### Software\n\n- [GitHub Desktop](https://desktop.github.com) - Simplifies local repository management\n- [Git Client](https://git-scm.com) - Version control system for cloning/committing code\n\n### Hardware\n\n- Computer - Needed for coding and repository management\n- Internet Connection - Essential for accessing GitHub and syncing changes\n\n### Projects to Explore\n\n- [One Army GitHub](https://github.com/onearmy)\n- [Darigov Research GitHub](https://github.com/darigovresearch)",
"references": "## References\n\n### GitHub Repositories\n\n- [One Army Projects](https://github.com/onearmy)\n- [Darigov Research Projects](https://github.com/darigovresearch)\n- [One Army GitHub](https://github.com/onearmy)\n- [Darigov Research GitHub](https://github.com/darigovresearch)\n\n### Websites\n\n- [Darigov Research Website](https://www.darigovresearch.com)"
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---
title: Contribute to open source projects
slug: contribute-to-open-source-projects
description: ### Getting Started with Open Source Contribution
Starting to contribute to open source projects can be daunting. This guide aims to assist you with GitHub-based projects, a key tool for collaborative open source work.
tags: ["product","starterkit","research"]
category: uncategorized
difficulty: Easy
time: < 1 hour
location: London, United Kingdom of Great Britain and Northern Ireland (the)
---
import { Image } from 'astro:assets'
# Contribute to open source projects
<Image src={import('./0_Intro_title.png')} alt="Contribute to open source projects" />
### Getting Started with Open Source Contribution
Starting to contribute to open source projects can be daunting. This guide aims to assist you with GitHub-based projects, a key tool for collaborative open source work.
User Location: London, United Kingdom of Great Britain and Northern Ireland (the)
## Steps
### Step 1: Find a project
### Finding a Project
Explore various open-source projects to find one that interests you. Many organizations actively welcome collaborators. For a starting point, consider visiting the following resources:
- [One Army Projects](https://github.com/onearmy)
- [Darigov Research Projects](https://github.com/darigovresearch)
<Image src={import('./1_find_a_project.png')} alt="1_find_a_project.png" />
### Step 2: Readme & contributing guide
Please refer to the README and contributing guidelines. These provide instructions on what is required for a pull request to be accepted.
<Image src={import('./2_readme.png')} alt="2_readme.png" />
<Image src={import('./2_contributing_guideline.png')} alt="2_contributing_guideline.png" />
### Step 3: View the issues
### Contributing Guidelines
Review the open issues to find tasks you can address. For newcomers, we suggest selecting tasks that are quick and easy to complete.
<Image src={import('./3_view_the_issues.png')} alt="3_view_the_issues.png" />
### Step 4: Sign in/Sign up
### Instructions
Create an account or sign in if you already have one by following the user interface steps.
<Image src={import('./4_sign_in.png')} alt="4_sign_in.png" />
### Step 5: Fork the repository
To fork a repository, click the fork button when signed in. The URL and page header will reflect your account name, confirming the repository is now associated with your account.
<Image src={import('./5_fork.png')} alt="5_fork.png" />
### Step 6: Make changes
In the browser, edit files by clicking their name and the edit button, which opens a page for editing and previewing changes. For multiple uploads, use the upload button to drag and drop files, providing a message about the changes at the bottom.
To edit locally, clone the repository, make updates, commit changes, and push them to the server. For GitHub projects, the desktop app is recommended for its intuitive interface.
<Image src={import('./6_edit_file.png')} alt="6_edit_file.png" />
<Image src={import('./6_preview_changes.png')} alt="6_preview_changes.png" />
<Image src={import('./6_commit_message.png')} alt="6_commit_message.png" />
### Step 7: Make a pull request
Adhere to any templates or guidelines in the repository. Provide a clear name and brief description of your changes. Reference issues by their numbers to link to the relevant context. You may need to revise based on auto-generated tests or feedback from repository maintainers.
<Image src={import('./7_pull_request.png')} alt="7_pull_request.png" />
<Image src={import('./7_template.png')} alt="7_template.png" />
<Image src={import('./7_complete_pull_request.png')} alt="7_complete_pull_request.png" />
### Step 8: Wait for it to be Merged
### How to Contribute to Open Source
Once your changes are approved by repository maintainers, your contribution to open source will be official.
For further details, watch the tutorial video related to this guide.
Explore the One Army GitHub to find repositories for contributions: [One Army GitHub](https://github.com/onearmy).
For additional information on open source projects, visit our [website](https://www.darigovresearch.com) and [GitHub repository](https://github.com/darigovresearch).

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## References
### GitHub Repositories
- [One Army Projects](https://github.com/onearmy)
- [Darigov Research Projects](https://github.com/darigovresearch)
- [One Army GitHub](https://github.com/onearmy)
- [Darigov Research GitHub](https://github.com/darigovresearch)
### Websites
- [Darigov Research Website](https://www.darigovresearch.com)

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Here's the structured breakdown of required components from the tutorial:
### Tools
- [GitHub Account](https://github.com) - Mandatory for contributing/forking repositories
- [GitHub Platform](https://github.com) - Primary interface for code hosting and collaboration
- Web Browser - For editing files directly via GitHub's web interface
### Software
- [GitHub Desktop](https://desktop.github.com) - Simplifies local repository management
- [Git Client](https://git-scm.com) - Version control system for cloning/committing code
### Hardware
- Computer - Needed for coding and repository management
- Internet Connection - Essential for accessing GitHub and syncing changes
### Projects to Explore
- [One Army GitHub](https://github.com/onearmy)
- [Darigov Research GitHub](https://github.com/darigovresearch)

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---
title: Create a bench with 2x4 beams
slug: create-a-bench-with-2x4-beams
description: This tutorial explains how to build a bench using 2x4 extruded beams. The finished bench will weigh over 80 pounds (approximately 36 kilograms).
tags: ["untagged","extrusion","PP"]
category: Products
difficulty: Medium
time: < 1 week
keywords: bench building, extruded beams, DIY furniture, PP plastic, woodworking tools, assembly instructions, bench construction, V4 extruder, Baltimore DIY, homemade bench
location: Baltimore, United States of America (the)
---
# Create a bench with 2x4 beams
![Create a bench with 2x4 beams](0F336C0F-D886-450F-ACB0-018852CC6746.jpeg)
This tutorial explains how to build a bench using 2x4 extruded beams. The finished bench will weigh over 80 pounds (approximately 36 kilograms).
User Location: Baltimore, United States of America (the)
## Steps
### Step 1: Prepare your material and equipment
This process requires the following tools and equipment:
- V4 Extruder
- 2x4 mold (1.5 in x 3.5 in x 6 ft)
- Approximately 85 lbs (38.6 kg) of shredded PP plastic
- Cooling tank
- Miter saw
- Drill
- Drill bits
- Deck screws
Once you have gathered all your materials and equipment, you are ready to begin.
![IMG_2914.jpg](./IMG_2914.jpg)
![0B5036DC-73BC-43D1-A866-388DC1EF0E54.jpeg](./0B5036DC-73BC-43D1-A866-388DC1EF0E54.jpeg)
### Step 2: Prep
Ensure all plastic is thoroughly cleaned, sorted by type (and color if necessary), and shredded to the desired flake size. For our bench, we used PP (#5) plastic.
![8E4E2360-A83C-4F60-B586-FC2A0CD4E900.jpeg](./8E4E2360-A83C-4F60-B586-FC2A0CD4E900.jpeg)
### Step 3: Extrude
With the plastic prepared, it is ready for extrusion into beams. Set the extruder temperature to 240°C (464°F) for PP plastic. Attach the mold. Begin extruding at 45-50 RPM, ensuring the hopper remains filled. Once the 6-foot (1.83-meter) mold is filled, disconnect it and place it in a cooling tank with cold water for approximately 20 minutes. After the plastic solidifies, remove it from the mold. Repeat until you have eight 6-foot beams.
![41A2A2FB-D5D0-4338-8D7C-9D86910A5AFD.png](./41A2A2FB-D5D0-4338-8D7C-9D86910A5AFD.png)
![3E4055E8-9696-4D7F-84C0-282E2F72F0CF.jpeg](./3E4055E8-9696-4D7F-84C0-282E2F72F0CF.jpeg)
![75723621-75E5-4EE8-9A56-33FFAB013207.jpeg](./75723621-75E5-4EE8-9A56-33FFAB013207.jpeg)
### Step 4: Cut
The beams should first be trimmed to remove any excess material at the ends. Next, cut the beams to the specified dimensions using a chop saw:
- (4) beams, each 5 feet 4 inches (163 cm) for the Benchtop
- (1) beam, 60 inches (152 cm) for Ground Support
- (4) beams, each 16 inches (41 cm) for the Legs
- (6) beams, each 15 inches (38 cm) for the Braces
- (2) beams, each 11 1/4 inches (29 cm)
![9EB14FD3-C6DB-446D-B4A3-96862F864829.png](./9EB14FD3-C6DB-446D-B4A3-96862F864829.png)
### Step 5: Staging
### Assembly Instructions
Lay out the four longest beams side by side to form the bench top, maintaining a spacing of approximately 0.25 inches (6.35 mm) between each. Attach the braces at the ends of the bench top.
![C6BE9A60-C56D-4F45-844D-35403C94FE3F.jpeg](./C6BE9A60-C56D-4F45-844D-35403C94FE3F.jpeg)
### Step 6: Assemble
At this stage, attach the beams using 2.5-inch (6.35 cm) deck screws. Pre-drill pilot holes to prevent cracking.
![690FCC2F-B093-41A3-BA71-DE0A7291EA13.jpeg](./690FCC2F-B093-41A3-BA71-DE0A7291EA13.jpeg)
### Step 7: Attaching legs
Begin assembling the bench on a tarp to collect drill shavings for potential reuse. Position the 16-inch (40.64 cm) beams at each corner as legs. Drill pilot holes and secure with screws.
![20177182-8578-4860-B090-5C4EE57F8C14.jpeg](./20177182-8578-4860-B090-5C4EE57F8C14.jpeg)
### Step 8: Attaching supports and braces
With the bench top and legs prepared, the next step is to reinforce the structure. Position the 15-inch (38 cm) beams between the legs as braces. Next, use the 11 1/4 inch (28.5 cm) beams to install a perpendicular support, connecting the bench top to the 60-inch (152 cm) beam that spans the base.
![1D8056DD-DCEC-4F02-B349-B629583EB24D.jpeg](./1D8056DD-DCEC-4F02-B349-B629583EB24D.jpeg)
![6F3DF443-481D-438A-B68E-BCA7C550AB41.jpeg](./6F3DF443-481D-438A-B68E-BCA7C550AB41.jpeg)
### Step 9: Enjoy!
Choose a suitable location to install your bench, such as a backyard or park.
![4C777FB3-02A1-4140-9D1E-3A972B663873.jpeg](./4C777FB3-02A1-4140-9D1E-3A972B663873.jpeg)
![F18ED2D8-B35D-40B4-941E-A843A0870B2C.jpeg](./F18ED2D8-B35D-40B4-941E-A843A0870B2C.jpeg)
![21F32179-FAE1-4CAA-806C-B5C53C15ABC6.jpeg](./21F32179-FAE1-4CAA-806C-B5C53C15ABC6.jpeg)
## Resources
To build a bench using 2x4 extruded beams, you’ll need the following items grouped by category:
### Tools & Equipment
- V4 Extruder
- 2x4 mold (1.5 in x 3.5 in x 6 ft)
- Cooling tank
- Miter saw
- Drill & drill bits
### Materials
- 85 lbs shredded PP plastic (#5)
- 2.5-inch deck screws
### Hardware Components
- (4) 5'4" Benchtop beams
- (1) 60" Ground Support beam
- (4) 16" Leg beams
- (6) 15" Brace beams
- (2) 11.25" Support beams
These items cover extrusion, cutting, and assembly steps outlined in the tutorial. The process involves shredding plastic, molding beams, and constructing the bench with precise cuts and screws.
## References
### Articles
https://pri-plastics.com/understanding-plastic-extrusion-a-comprehensive-guide/\
https://www.onearmy.earth/news/extrusion-machine
### Books
https://www.barnesandnoble.com/w/extrusion-harold-f-giles-jr/1111448551
### YouTube
https://www.youtube.com/watch?v=tGc-Z7TtiVg\
https://www.youtube.com/watch?v=1A05nDBKzVc\
https://www.youtube.com/watch?v=9Hmp4K3NwB0
### Opensource Designs
https://community.preciousplastic.com/library/make-a-bench-with-beams

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---
title: Create a bench with 2x4 beams
slug: create-a-bench-with-2x4-beams
description: This tutorial explains how to build a bench using 2x4 extruded beams. The finished bench will weigh over 80 pounds (approximately 36 kilograms).
tags: ["untagged","extrusion","PP"]
category: Products
difficulty: Medium
time: < 1 week
location: Baltimore, United States of America (the)
---
import { Image } from 'astro:assets'
# Create a bench with 2x4 beams
<Image src={import('./0F336C0F-D886-450F-ACB0-018852CC6746.jpeg')} alt="Create a bench with 2x4 beams" />
This tutorial explains how to build a bench using 2x4 extruded beams. The finished bench will weigh over 80 pounds (approximately 36 kilograms).
User Location: Baltimore, United States of America (the)
## Steps
### Step 1: Prepare your material and equipment
This process requires the following tools and equipment:
- V4 Extruder
- 2x4 mold (1.5 in x 3.5 in x 6 ft)
- Approximately 85 lbs (38.6 kg) of shredded PP plastic
- Cooling tank
- Miter saw
- Drill
- Drill bits
- Deck screws
Once you have gathered all your materials and equipment, you are ready to begin.
<Image src={import('./IMG_2914.jpg')} alt="IMG_2914.jpg" />
<Image src={import('./0B5036DC-73BC-43D1-A866-388DC1EF0E54.jpeg')} alt="0B5036DC-73BC-43D1-A866-388DC1EF0E54.jpeg" />
### Step 2: Prep
Ensure all plastic is thoroughly cleaned, sorted by type (and color if necessary), and shredded to the desired flake size. For our bench, we used PP (#5) plastic.
<Image src={import('./8E4E2360-A83C-4F60-B586-FC2A0CD4E900.jpeg')} alt="8E4E2360-A83C-4F60-B586-FC2A0CD4E900.jpeg" />
### Step 3: Extrude
With the plastic prepared, it is ready for extrusion into beams. Set the extruder temperature to 240°C (464°F) for PP plastic. Attach the mold. Begin extruding at 45-50 RPM, ensuring the hopper remains filled. Once the 6-foot (1.83-meter) mold is filled, disconnect it and place it in a cooling tank with cold water for approximately 20 minutes. After the plastic solidifies, remove it from the mold. Repeat until you have eight 6-foot beams.
<Image src={import('./41A2A2FB-D5D0-4338-8D7C-9D86910A5AFD.png')} alt="41A2A2FB-D5D0-4338-8D7C-9D86910A5AFD.png" />
<Image src={import('./3E4055E8-9696-4D7F-84C0-282E2F72F0CF.jpeg')} alt="3E4055E8-9696-4D7F-84C0-282E2F72F0CF.jpeg" />
<Image src={import('./75723621-75E5-4EE8-9A56-33FFAB013207.jpeg')} alt="75723621-75E5-4EE8-9A56-33FFAB013207.jpeg" />
### Step 4: Cut
The beams should first be trimmed to remove any excess material at the ends. Next, cut the beams to the specified dimensions using a chop saw:
- (4) beams, each 5 feet 4 inches (163 cm) for the Benchtop
- (1) beam, 60 inches (152 cm) for Ground Support
- (4) beams, each 16 inches (41 cm) for the Legs
- (6) beams, each 15 inches (38 cm) for the Braces
- (2) beams, each 11 1/4 inches (29 cm)
<Image src={import('./9EB14FD3-C6DB-446D-B4A3-96862F864829.png')} alt="9EB14FD3-C6DB-446D-B4A3-96862F864829.png" />
### Step 5: Staging
### Assembly Instructions
Lay out the four longest beams side by side to form the bench top, maintaining a spacing of approximately 0.25 inches (6.35 mm) between each. Attach the braces at the ends of the bench top.
<Image src={import('./C6BE9A60-C56D-4F45-844D-35403C94FE3F.jpeg')} alt="C6BE9A60-C56D-4F45-844D-35403C94FE3F.jpeg" />
### Step 6: Assemble
At this stage, attach the beams using 2.5-inch (6.35 cm) deck screws. Pre-drill pilot holes to prevent cracking.
<Image src={import('./690FCC2F-B093-41A3-BA71-DE0A7291EA13.jpeg')} alt="690FCC2F-B093-41A3-BA71-DE0A7291EA13.jpeg" />
### Step 7: Attaching legs
Begin assembling the bench on a tarp to collect drill shavings for potential reuse. Position the 16-inch (40.64 cm) beams at each corner as legs. Drill pilot holes and secure with screws.
<Image src={import('./20177182-8578-4860-B090-5C4EE57F8C14.jpeg')} alt="20177182-8578-4860-B090-5C4EE57F8C14.jpeg" />
### Step 8: Attaching supports and braces
With the bench top and legs prepared, the next step is to reinforce the structure. Position the 15-inch (38 cm) beams between the legs as braces. Next, use the 11 1/4 inch (28.5 cm) beams to install a perpendicular support, connecting the bench top to the 60-inch (152 cm) beam that spans the base.
<Image src={import('./1D8056DD-DCEC-4F02-B349-B629583EB24D.jpeg')} alt="1D8056DD-DCEC-4F02-B349-B629583EB24D.jpeg" />
<Image src={import('./6F3DF443-481D-438A-B68E-BCA7C550AB41.jpeg')} alt="6F3DF443-481D-438A-B68E-BCA7C550AB41.jpeg" />
### Step 9: Enjoy!
Choose a suitable location to install your bench, such as a backyard or park.
<Image src={import('./4C777FB3-02A1-4140-9D1E-3A972B663873.jpeg')} alt="4C777FB3-02A1-4140-9D1E-3A972B663873.jpeg" />
<Image src={import('./F18ED2D8-B35D-40B4-941E-A843A0870B2C.jpeg')} alt="F18ED2D8-B35D-40B4-941E-A843A0870B2C.jpeg" />
<Image src={import('./21F32179-FAE1-4CAA-806C-B5C53C15ABC6.jpeg')} alt="21F32179-FAE1-4CAA-806C-B5C53C15ABC6.jpeg" />

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### Articles
https://pri-plastics.com/understanding-plastic-extrusion-a-comprehensive-guide/\
https://www.onearmy.earth/news/extrusion-machine
### Books
https://www.barnesandnoble.com/w/extrusion-harold-f-giles-jr/1111448551
### YouTube
https://www.youtube.com/watch?v=tGc-Z7TtiVg\
https://www.youtube.com/watch?v=1A05nDBKzVc\
https://www.youtube.com/watch?v=9Hmp4K3NwB0
### Opensource Designs
https://community.preciousplastic.com/library/make-a-bench-with-beams

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To build a bench using 2x4 extruded beams, you’ll need the following items grouped by category:
### Tools & Equipment
- V4 Extruder
- 2x4 mold (1.5 in x 3.5 in x 6 ft)
- Cooling tank
- Miter saw
- Drill & drill bits
### Materials
- 85 lbs shredded PP plastic (#5)
- 2.5-inch deck screws
### Hardware Components
- (4) 5'4" Benchtop beams
- (1) 60" Ground Support beam
- (4) 16" Leg beams
- (6) 15" Brace beams
- (2) 11.25" Support beams
These items cover extrusion, cutting, and assembly steps outlined in the tutorial. The process involves shredding plastic, molding beams, and constructing the bench with precise cuts and screws.

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---
title: Create a lamp with translucent HDPE
slug: create-a-lamp-with-translucent-hdpe
description: Hello, we created a lamp to explore translucent HDPE properties. By sorting shredded transparent and colored bottle caps, you achieve a liquid-like effect. The key is in your color choice, allowing for diverse visual outcomes.
tags: ["injection","product","HDPE"]
category: Products
difficulty: Medium
time: < 5 hours
keywords: HDPE lamp, translucent lamp design, DIY HDPE lamp, colored bottle caps lamp, injection molding lamp, laser cut lamp components, liquid-light effect lamp, customized lamp assembly, makerspace lamp project, eco-friendly lamp design
location: Donostia / San Sebastian, Spain
---
# Create a lamp with translucent HDPE
![Create a lamp with translucent HDPE](Argitu-186cae2dcf4.jpg)
Hello, we created a lamp to explore translucent HDPE properties. By sorting shredded transparent and colored bottle caps, you achieve a liquid-like effect. The key is in your color choice, allowing for diverse visual outcomes.
User Location: Donostia / San Sebastian, Spain
## Steps
### Step 1: Sorting and Shredding
Collect HDPE bottle caps from a local source. To achieve a liquid-light effect for your lamp, use both transparent and colored caps. Adding a small amount of shredded colored plastic will tint and alter the final appearance. Sort and shred the plastic carefully.
![SORTING_1-186cb03e4a8.JPG](./SORTING_1-186cb03e4a8.JPG)
![SORTING_2-186cb040342.JPG](./SORTING_2-186cb040342.JPG)
![SORTING_4-186cb04d62f.JPG](./SORTING_4-186cb04d62f.JPG)
### Step 2: Injection moulding
In the initial image, the light bulb is positioned between two discs. Begin by creating the discs using injection molding. The mold has a thin wall thickness of 3 millimeters (0.12 inches). Refer to the Academy for melting temperatures for HDPE. Experiment with various color combinations. Each disc requires less than 30 grams (1.06 ounces) of material, so adding 3 or 4 grams (0.11 or 0.14 ounces) of color will suffice to tint the plastic.
![MOULD_2-186cb095ed3.JPG](./MOULD_2-186cb095ed3.JPG)
![MOULDING-186cb4be2bc.JPG](./MOULDING-186cb4be2bc.JPG)
![COLOURS-186cb0ff52a.JPG](./COLOURS-186cb0ff52a.JPG)
### Step 3: Laser cut
The clamp for the discs is constructed from wood. We utilized a laser cutting machine at a local makerspace to produce the wooden components. The wood is 0.39 inches (1 cm) thick, and the CAD drawings are included in the download package. The clamp is tailored to accommodate a specific lamp holder and bulb, but you may adjust the design for lamp holders available at local stores. The wooden pieces were later spray-painted.
A small square indentation must be cut from the disc to allow it to attach to the wooden part securely. This feature enables you to swap out discs without using adhesive, facilitating various lighting effects.
![MOUNT-186cb1e46e2.JPG](./MOUNT-186cb1e46e2.JPG)
![Laser cut-186cb1fb967.JPG](./Laser_cut-186cb1fb967.JPG)
![ZURA_MARGOTU-186cb222c4a.JPG](./ZURA_MARGOTU-186cb222c4a.JPG)
### Step 4: Assembling the light and finding a place for it.
Assembling the lamp should be quick, as all parts are designed to fit securely. If the structure is unstable, apply glue for reinforcement. You can place it on a bedside table, a desk, or hang it. We would appreciate seeing your completed work.
![AG_1-186cb3a5f72.JPG](./AG_1-186cb3a5f72.JPG)
![AG_2-186cb3a6efd.JPG](./AG_2-186cb3a6efd.JPG)
![AG_3-186cb3a8044.JPG](./AG_3-186cb3a8044.JPG)
## Resources
To create the HDPE lamp described, you'll need the following tools, software, hardware, and materials:
### Tools
- HDPE bottle cap collection (local sources in Donostia/San Sebastian)
- Plastic shredder for processing caps
- Color sorting system for translucent/colored caps
- Injection molding equipment with 3mm-thick molds
- Spray paint for wooden components
### Software
- CAD software to modify wooden clamp designs (drawings included)
### Hardware
- Laser cutting machine (available at local makerspaces)
- Injection molding system for disc production
- Standard lamp holder and bulb assembly
### Materials
- Transparent/colored HDPE bottle caps
- Shredded colored plastic (3-4g per disc for tinting)
- 1 cm thick wood sheets for clamp construction
- Spray-paintable wooden components
- Adhesive (optional reinforcement)
The lamp's modular design allows customization using locally available materials and makerspace equipment. Total material per disc stays under 30g HDPE with <5g color additives[1][2][4][5].
## References
**References**
No external reference links were provided in the text to process.

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"content": "Hello, we created a lamp to explore translucent HDPE properties. By sorting shredded transparent and colored bottle caps, you achieve a liquid-like effect. The key is in your color choice, allowing for diverse visual outcomes.\n\n\nUser Location: Donostia / San Sebastian, Spain\n\nCollect HDPE bottle caps from a local source. To achieve a liquid-light effect for your lamp, use both transparent and colored caps. Adding a small amount of shredded colored plastic will tint and alter the final appearance. Sort and shred the plastic carefully.\n\nIn the initial image, the light bulb is positioned between two discs. Begin by creating the discs using injection molding. The mold has a thin wall thickness of 3 millimeters (0.12 inches). Refer to the Academy for melting temperatures for HDPE. Experiment with various color combinations. Each disc requires less than 30 grams (1.06 ounces) of material, so adding 3 or 4 grams (0.11 or 0.14 ounces) of color will suffice to tint the plastic.\n\nThe clamp for the discs is constructed from wood. We utilized a laser cutting machine at a local makerspace to produce the wooden components. The wood is 0.39 inches (1 cm) thick, and the CAD drawings are included in the download package. The clamp is tailored to accommodate a specific lamp holder and bulb, but you may adjust the design for lamp holders available at local stores. The wooden pieces were later spray-painted.\n\nA small square indentation must be cut from the disc to allow it to attach to the wooden part securely. This feature enables you to swap out discs without using adhesive, facilitating various lighting effects.\n\nAssembling the lamp should be quick, as all parts are designed to fit securely. If the structure is unstable, apply glue for reinforcement. You can place it on a bedside table, a desk, or hang it. We would appreciate seeing your completed work.",
"keywords": "HDPE lamp, translucent lamp design, DIY HDPE lamp, colored bottle caps lamp, injection molding lamp, laser cut lamp components, liquid-light effect lamp, customized lamp assembly, makerspace lamp project, eco-friendly lamp design",
"resources": "To create the HDPE lamp described, you'll need the following tools, software, hardware, and materials:\n\n### Tools\n\n- HDPE bottle cap collection (local sources in Donostia/San Sebastian)\n- Plastic shredder for processing caps\n- Color sorting system for translucent/colored caps\n- Injection molding equipment with 3mm-thick molds\n- Spray paint for wooden components\n\n### Software\n\n- CAD software to modify wooden clamp designs (drawings included)\n\n### Hardware\n\n- Laser cutting machine (available at local makerspaces)\n- Injection molding system for disc production\n- Standard lamp holder and bulb assembly\n\n### Materials\n\n- Transparent/colored HDPE bottle caps\n- Shredded colored plastic (3-4g per disc for tinting)\n- 1 cm thick wood sheets for clamp construction\n- Spray-paintable wooden components\n- Adhesive (optional reinforcement)\n\nThe lamp's modular design allows customization using locally available materials and makerspace equipment. Total material per disc stays under 30g HDPE with <5g color additives[1][2][4][5].",
"references": "**References**\n\nNo external reference links were provided in the text to process."
}

70
howtos/create-a-lamp-with-translucent-hdpe/index.mdx Normal file
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---
title: Create a lamp with translucent HDPE
slug: create-a-lamp-with-translucent-hdpe
description: Hello, we created a lamp to explore translucent HDPE properties. By sorting shredded transparent and colored bottle caps, you achieve a liquid-like effect. The key is in your color choice, allowing for diverse visual outcomes.
tags: ["injection","product","HDPE"]
category: Products
difficulty: Medium
time: < 5 hours
location: Donostia / San Sebastian, Spain
---
import { Image } from 'astro:assets'
# Create a lamp with translucent HDPE
<Image src={import('./Argitu-186cae2dcf4.jpg')} alt="Create a lamp with translucent HDPE" />
Hello, we created a lamp to explore translucent HDPE properties. By sorting shredded transparent and colored bottle caps, you achieve a liquid-like effect. The key is in your color choice, allowing for diverse visual outcomes.
User Location: Donostia / San Sebastian, Spain
## Steps
### Step 1: Sorting and Shredding
Collect HDPE bottle caps from a local source. To achieve a liquid-light effect for your lamp, use both transparent and colored caps. Adding a small amount of shredded colored plastic will tint and alter the final appearance. Sort and shred the plastic carefully.
<Image src={import('./SORTING_1-186cb03e4a8.JPG')} alt="SORTING_1-186cb03e4a8.JPG" />
<Image src={import('./SORTING_2-186cb040342.JPG')} alt="SORTING_2-186cb040342.JPG" />
<Image src={import('./SORTING_4-186cb04d62f.JPG')} alt="SORTING_4-186cb04d62f.JPG" />
### Step 2: Injection moulding
In the initial image, the light bulb is positioned between two discs. Begin by creating the discs using injection molding. The mold has a thin wall thickness of 3 millimeters (0.12 inches). Refer to the Academy for melting temperatures for HDPE. Experiment with various color combinations. Each disc requires less than 30 grams (1.06 ounces) of material, so adding 3 or 4 grams (0.11 or 0.14 ounces) of color will suffice to tint the plastic.
<Image src={import('./MOULD_2-186cb095ed3.JPG')} alt="MOULD_2-186cb095ed3.JPG" />
<Image src={import('./MOULDING-186cb4be2bc.JPG')} alt="MOULDING-186cb4be2bc.JPG" />
<Image src={import('./COLOURS-186cb0ff52a.JPG')} alt="COLOURS-186cb0ff52a.JPG" />
### Step 3: Laser cut
The clamp for the discs is constructed from wood. We utilized a laser cutting machine at a local makerspace to produce the wooden components. The wood is 0.39 inches (1 cm) thick, and the CAD drawings are included in the download package. The clamp is tailored to accommodate a specific lamp holder and bulb, but you may adjust the design for lamp holders available at local stores. The wooden pieces were later spray-painted.
A small square indentation must be cut from the disc to allow it to attach to the wooden part securely. This feature enables you to swap out discs without using adhesive, facilitating various lighting effects.
<Image src={import('./MOUNT-186cb1e46e2.JPG')} alt="MOUNT-186cb1e46e2.JPG" />
<Image src={import('./Laser_cut-186cb1fb967.JPG')} alt="Laser cut-186cb1fb967.JPG" />
<Image src={import('./ZURA_MARGOTU-186cb222c4a.JPG')} alt="ZURA_MARGOTU-186cb222c4a.JPG" />
### Step 4: Assembling the light and finding a place for it.
Assembling the lamp should be quick, as all parts are designed to fit securely. If the structure is unstable, apply glue for reinforcement. You can place it on a bedside table, a desk, or hang it. We would appreciate seeing your completed work.
<Image src={import('./AG_1-186cb3a5f72.JPG')} alt="AG_1-186cb3a5f72.JPG" />
<Image src={import('./AG_2-186cb3a6efd.JPG')} alt="AG_2-186cb3a6efd.JPG" />
<Image src={import('./AG_3-186cb3a8044.JPG')} alt="AG_3-186cb3a8044.JPG" />

3
howtos/create-a-lamp-with-translucent-hdpe/references.md Normal file
View File

@ -0,0 +1,3 @@
**References**
No external reference links were provided in the text to process.

29
howtos/create-a-lamp-with-translucent-hdpe/resources.md Normal file
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@ -0,0 +1,29 @@
To create the HDPE lamp described, you'll need the following tools, software, hardware, and materials:
### Tools
- HDPE bottle cap collection (local sources in Donostia/San Sebastian)
- Plastic shredder for processing caps
- Color sorting system for translucent/colored caps
- Injection molding equipment with 3mm-thick molds
- Spray paint for wooden components
### Software
- CAD software to modify wooden clamp designs (drawings included)
### Hardware
- Laser cutting machine (available at local makerspaces)
- Injection molding system for disc production
- Standard lamp holder and bulb assembly
### Materials
- Transparent/colored HDPE bottle caps
- Shredded colored plastic (3-4g per disc for tinting)
- 1 cm thick wood sheets for clamp construction
- Spray-paintable wooden components
- Adhesive (optional reinforcement)
The lamp's modular design allows customization using locally available materials and makerspace equipment. Total material per disc stays under 30g HDPE with <5g color additives[1][2][4][5].

176
howtos/create-a-notebook-with-sugar-cane-paper-and-pp/README.md Normal file
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@ -0,0 +1,176 @@
---
title: Create a Notebook with sugar cane paper and PP
slug: create-a-notebook-with-sugar-cane-paper-and-pp
description: ## How to Create a Notebook with Sugar Cane Paper and Custom Sheets
### Materials Needed:
- A 2mm (0.08 inches) sheet
- Sugar cane paper
- Jigsaw
- Marking tool
- Hole saw
- Rivets
- 10mm (0.39 inches) elastic
- 5/32 inch (4mm) drill
- Press
tags: ["PP","HDPE","sheetpress","collection"]
category: Products
difficulty: Medium
time: < 5 hours
keywords: notebook, sugar cane paper, custom sheets, DIY notebook, notebook assembly, elastic binding, rivet fastening, handmade notebook, made in Colombia, sustainable materials
location: Bogota, Colombia
---
# Create a Notebook with sugar cane paper and PP
![Create a Notebook with sugar cane paper and PP](Copia_de_Post-06.jpg)
## How to Create a Notebook with Sugar Cane Paper and Custom Sheets
### Materials Needed:
- A 2mm (0.08 inches) sheet
- Sugar cane paper
- Jigsaw
- Marking tool
- Hole saw
- Rivets
- 10mm (0.39 inches) elastic
- 5/32 inch (4mm) drill
- Press
User Location: Bogota, Colombia
## Steps
### Step 1: Create marks on your sheet
Choose a 2mm (0.08 inches) sheet; for this example, we use sheets sized 520mm x 520mm (20.47 inches x 20.47 inches).
Mark the sheet with the desired dimensions for the notebook covers using a marker or cutter. For repeated production, consider creating a template.
![_MG_2032.JPG](./_MG_2032.JPG)
![_MG_2049.JPG](./_MG_2049.JPG)
![_MG_2051.jpg](./_MG_2051.jpg)
### Step 2: Cut the sheet
Use a jigsaw with a metal-cutting blade to cut along the marked lines. Wear protective glasses and gloves for safety. Secure the sheet on the cutting table to prevent movement.
![_MG_2054.JPG](./_MG_2054.JPG)
![_MG_2058.JPG](./_MG_2058.JPG)
### Step 3: Clean the covers
To clean the edges of the covers, use a small knife for a smooth finish.
![_MG_2073.JPG](./_MG_2073.JPG)
### Step 4: Open holes
To prepare the notebook cover, drill holes for the elastic band using a 5/35" (3.57 mm) bit in the back cover and a 2" (50.8 mm) hole saw in the front. You may stack multiple covers for drilling, but use the hole saw individually to easily remove the cut-out. Always secure the covers and wear gloves and safety glasses for protection.
![_MG_2063.JPG](./_MG_2063.JPG)
![_MG_2061.JPG](./_MG_2061.JPG)
![_MG_2065.JPG](./_MG_2065.JPG)
### Step 5: Put the elastic on back cover
### Instructions for Attaching Elastic with Rivets
Use rivets to secure the elastic to the back cover. A rivet consists of two parts; position the elastic between these parts before fastening.
If a riveting machine is unavailable, a hammer can be used to close the rivet.
![_MG_2068.JPG](./_MG_2068.JPG)
![_MG_2072.JPG](./_MG_2072.JPG)
### Step 6: Cut the paper to desired size
If creating a specific size notebook, cut the paper to the desired dimensions; here, we use letter-size (8.5" x 11") paper to make half-letter (5.5" x 8.5").
![_MG_2075.jpg](./_MG_2075.jpg)
### Step 7: Fix everything for assembly
Prepare the covers and sheets for assembly. If a printed sheet is desired, do it now.
As we lack equipment to bind the notebooks, we use an external service for this process.
![_MG_2077.JPG](./_MG_2077.JPG)
### Step 8: And last but not least...
Stamp your products to clearly identify the materials used.
Enjoy your new notebook!
![20211130_133011.jpg](./20211130_133011.jpg)
![20211130_150142.jpg](./20211130_150142.jpg)
![20211130_150118.jpg](./20211130_150118.jpg)
## Resources
### Tools
- Jigsaw with metal-cutting blade
- 2" (50.8mm) hole saw
- 5/32" (4mm) drill bit
- Riveting machine or hammer
- Small knife/deburring tool
### Hardware
- 2mm sheet metal (520mm x 520mm)
- Sugar cane paper sheets
- 10mm elastic band
- Rivets
- Binding press (optional*)
### Software
- None required
*The tutorial mentions using an external binding service if a press is unavailable.
## References
Here is the requested list of references grouped by category, presented as Markdown links without comments:
### Articles
- [DIY Paper Notebook : 8 Steps (with Pictures) - Instructables](https://www.instructables.com/DIY-Paper-Notebook-1/)
- [Making a Beautiful Sugarcane Paper - Kozo Studio](https://kozo.studio/blogs/journal/making-a-beautiful-sugarcane-paper)
### YouTube Tutorials
- [Creating an open-source book with Jupyter Book and Jupytext](https://www.youtube.com/watch?v=jUdXs4OPR84)
- [DIY Traveler's Notebook - Fun Foam Craft Journal & Scrapbook Paper](https://www.youtube.com/watch?v=2Vfwxonwc7Y)
### Product Suppliers
- [Sugar Cane Notepad - K. J. Noakes](https://kjnoakes.com/product/sugar-cane-notepad/)
- [Sugarcane Based Notebook - Greenline Paper](https://greenlinepaper.com/shop/pad/)
- [Sugarcane Paper Notebook A5 - HelloPrint](https://www.helloprint.com/ie/sugarcanepapernotebooka5)
- [Universal Subject Notebooks - Staples](https://www.staples.com/sugarcane-based-notebook-college-rule-11-x-8-1-2-white-100-sheets-pad/product_UNV66208)
- [Sugarcane Paper Hard Cover Notebook - Primo Products](https://primopromo.com.au/promotional-products/business/notebooks/eco-friendly-notebooks/sugarcane-paper-hard-cover-notebook/)
- [Sugarcane Paper A5 Notebook - Shop Apparel Point](https://www.shop.apparel-point.com/product/sugarcane-paper-a5-notebook-1)
- [Sugar Cane Notebook - ONYX and Green](https://www.onyxandgreen.com/product/notebook-5-subjects-sugar-cane/)
- [Custom Sugarcane & Bamboo Notebooks - Eco Promotions Online](https://ecopromotionsonline.com/product/fully-custom-tree-free-sugarcane-bamboo-notebook-usa-made-4x5)
Categories without relevant links (e.g., *Books*, *Papers*, *Opensource Designs*) have been omitted.

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"text": "Use a jigsaw with a metal-cutting blade to cut along the marked lines. Wear protective glasses and gloves for safety. Secure the sheet on the cutting table to prevent movement.",
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"title": "Cut the sheet"
},
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"title": "Clean the covers",
"text": "To clean the edges of the covers, use a small knife for a smooth finish."
},
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"text": "To prepare the notebook cover, drill holes for the elastic band using a 5/35\" (3.57 mm) bit in the back cover and a 2\" (50.8 mm) hole saw in the front. You may stack multiple covers for drilling, but use the hole saw individually to easily remove the cut-out. Always secure the covers and wear gloves and safety glasses for protection.",
"title": "Open holes"
},
{
"text": "### Instructions for Attaching Elastic with Rivets\n\nUse rivets to secure the elastic to the back cover. A rivet consists of two parts; position the elastic between these parts before fastening.\n\nIf a riveting machine is unavailable, a hammer can be used to close the rivet.",
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}
],
"_animationKey": "uniqueisapl",
"title": "Put the elastic on back cover"
},
{
"_animationKey": "uniquex3tafj",
"text": "If creating a specific size notebook, cut the paper to the desired dimensions; here, we use letter-size (8.5\" x 11\") paper to make half-letter (5.5\" x 8.5\").",
"images": [
{
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"type": "image/jpeg",
"src": "/resources/howtos/create-a-notebook-with-sugar-cane-paper-and-pp/_mg_2075.jpg",
"alt": "_MG_2075.jpg"
}
],
"title": "Cut the paper to desired size"
},
{
"_animationKey": "uniqued2heb",
"title": "Fix everything for assembly",
"images": [
{
"downloadUrl": "https://firebasestorage.googleapis.com/v0/b/onearmyworld.appspot.com/o/uploads%2Fhowtos%2Fs1WGE8fWZNoxB7So7uFL%2F_MG_2077.JPG?alt=media&token=edd49c0b-bdcc-4a6f-ba41-584e2eaeae41",
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"updated": "2021-12-03T18:11:12.414Z",
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"timeCreated": "2021-12-03T18:11:12.414Z",
"src": "/resources/howtos/create-a-notebook-with-sugar-cane-paper-and-pp/_mg_2077.jpg",
"alt": "_MG_2077.JPG"
}
],
"text": "Prepare the covers and sheets for assembly. If a printed sheet is desired, do it now.\n\nAs we lack equipment to bind the notebooks, we use an external service for this process."
},
{
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{
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"alt": "20211130_133011.jpg"
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"alt": "20211130_150142.jpg"
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],
"title": "And last but not least...",
"text": "Stamp your products to clearly identify the materials used.\n\nEnjoy your new notebook!",
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"content": "## How to Create a Notebook with Sugar Cane Paper and Custom Sheets\n\n### Materials Needed:\n- A 2mm (0.08 inches) sheet\n- Sugar cane paper\n- Jigsaw\n- Marking tool\n- Hole saw\n- Rivets\n- 10mm (0.39 inches) elastic\n- 5/32 inch (4mm) drill\n- Press\n\n\nUser Location: Bogota, Colombia\n\nChoose a 2mm (0.08 inches) sheet; for this example, we use sheets sized 520mm x 520mm (20.47 inches x 20.47 inches). \n\nMark the sheet with the desired dimensions for the notebook covers using a marker or cutter. For repeated production, consider creating a template.\n\nUse a jigsaw with a metal-cutting blade to cut along the marked lines. Wear protective glasses and gloves for safety. Secure the sheet on the cutting table to prevent movement.\n\nTo clean the edges of the covers, use a small knife for a smooth finish.\n\nTo prepare the notebook cover, drill holes for the elastic band using a 5/35\" (3.57 mm) bit in the back cover and a 2\" (50.8 mm) hole saw in the front. You may stack multiple covers for drilling, but use the hole saw individually to easily remove the cut-out. Always secure the covers and wear gloves and safety glasses for protection.\n\n### Instructions for Attaching Elastic with Rivets\n\nUse rivets to secure the elastic to the back cover. A rivet consists of two parts; position the elastic between these parts before fastening.\n\nIf a riveting machine is unavailable, a hammer can be used to close the rivet.\n\nIf creating a specific size notebook, cut the paper to the desired dimensions; here, we use letter-size (8.5\" x 11\") paper to make half-letter (5.5\" x 8.5\").\n\nPrepare the covers and sheets for assembly. If a printed sheet is desired, do it now.\n\nAs we lack equipment to bind the notebooks, we use an external service for this process.\n\nStamp your products to clearly identify the materials used.\n\nEnjoy your new notebook!",
"keywords": "notebook, sugar cane paper, custom sheets, DIY notebook, notebook assembly, elastic binding, rivet fastening, handmade notebook, made in Colombia, sustainable materials",
"resources": "### Tools\n\n- Jigsaw with metal-cutting blade\n- 2\" (50.8mm) hole saw\n- 5/32\" (4mm) drill bit\n- Riveting machine or hammer\n- Small knife/deburring tool\n\n### Hardware\n\n- 2mm sheet metal (520mm x 520mm)\n- Sugar cane paper sheets\n- 10mm elastic band\n- Rivets\n- Binding press (optional*)\n\n### Software\n\n- None required\n\n*The tutorial mentions using an external binding service if a press is unavailable.",
"references": "Here is the requested list of references grouped by category, presented as Markdown links without comments:\n\n### Articles\n\n- [DIY Paper Notebook : 8 Steps (with Pictures) - Instructables](https://www.instructables.com/DIY-Paper-Notebook-1/)\n- [Making a Beautiful Sugarcane Paper - Kozo Studio](https://kozo.studio/blogs/journal/making-a-beautiful-sugarcane-paper)\n\n### YouTube Tutorials\n\n- [Creating an open-source book with Jupyter Book and Jupytext](https://www.youtube.com/watch?v=jUdXs4OPR84)\n- [DIY Traveler's Notebook - Fun Foam Craft Journal & Scrapbook Paper](https://www.youtube.com/watch?v=2Vfwxonwc7Y)\n\n### Product Suppliers\n\n- [Sugar Cane Notepad - K. J. Noakes](https://kjnoakes.com/product/sugar-cane-notepad/)\n- [Sugarcane Based Notebook - Greenline Paper](https://greenlinepaper.com/shop/pad/)\n- [Sugarcane Paper Notebook A5 - HelloPrint](https://www.helloprint.com/ie/sugarcanepapernotebooka5)\n- [Universal Subject Notebooks - Staples](https://www.staples.com/sugarcane-based-notebook-college-rule-11-x-8-1-2-white-100-sheets-pad/product_UNV66208)\n- [Sugarcane Paper Hard Cover Notebook - Primo Products](https://primopromo.com.au/promotional-products/business/notebooks/eco-friendly-notebooks/sugarcane-paper-hard-cover-notebook/)\n- [Sugarcane Paper A5 Notebook - Shop Apparel Point](https://www.shop.apparel-point.com/product/sugarcane-paper-a5-notebook-1)\n- [Sugar Cane Notebook - ONYX and Green](https://www.onyxandgreen.com/product/notebook-5-subjects-sugar-cane/)\n- [Custom Sugarcane & Bamboo Notebooks - Eco Promotions Online](https://ecopromotionsonline.com/product/fully-custom-tree-free-sugarcane-bamboo-notebook-usa-made-4x5)\n\nCategories without relevant links (e.g., *Books*, *Papers*, *Opensource Designs*) have been omitted."
}

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---
title: Create a Notebook with sugar cane paper and PP
slug: create-a-notebook-with-sugar-cane-paper-and-pp
description: ## How to Create a Notebook with Sugar Cane Paper and Custom Sheets
### Materials Needed:
- A 2mm (0.08 inches) sheet
- Sugar cane paper
- Jigsaw
- Marking tool
- Hole saw
- Rivets
- 10mm (0.39 inches) elastic
- 5/32 inch (4mm) drill
- Press
tags: ["PP","HDPE","sheetpress","collection"]
category: Products
difficulty: Medium
time: < 5 hours
location: Bogota, Colombia
---
import { Image } from 'astro:assets'
# Create a Notebook with sugar cane paper and PP
<Image src={import('./Copia_de_Post-06.jpg')} alt="Create a Notebook with sugar cane paper and PP" />
## How to Create a Notebook with Sugar Cane Paper and Custom Sheets
### Materials Needed:
- A 2mm (0.08 inches) sheet
- Sugar cane paper
- Jigsaw
- Marking tool
- Hole saw
- Rivets
- 10mm (0.39 inches) elastic
- 5/32 inch (4mm) drill
- Press
User Location: Bogota, Colombia
## Steps
### Step 1: Create marks on your sheet
Choose a 2mm (0.08 inches) sheet; for this example, we use sheets sized 520mm x 520mm (20.47 inches x 20.47 inches).
Mark the sheet with the desired dimensions for the notebook covers using a marker or cutter. For repeated production, consider creating a template.
<Image src={import('./_MG_2032.JPG')} alt="_MG_2032.JPG" />
<Image src={import('./_MG_2049.JPG')} alt="_MG_2049.JPG" />
<Image src={import('./_MG_2051.jpg')} alt="_MG_2051.jpg" />
### Step 2: Cut the sheet
Use a jigsaw with a metal-cutting blade to cut along the marked lines. Wear protective glasses and gloves for safety. Secure the sheet on the cutting table to prevent movement.
<Image src={import('./_MG_2054.JPG')} alt="_MG_2054.JPG" />
<Image src={import('./_MG_2058.JPG')} alt="_MG_2058.JPG" />
### Step 3: Clean the covers
To clean the edges of the covers, use a small knife for a smooth finish.
<Image src={import('./_MG_2073.JPG')} alt="_MG_2073.JPG" />
### Step 4: Open holes
To prepare the notebook cover, drill holes for the elastic band using a 5/35" (3.57 mm) bit in the back cover and a 2" (50.8 mm) hole saw in the front. You may stack multiple covers for drilling, but use the hole saw individually to easily remove the cut-out. Always secure the covers and wear gloves and safety glasses for protection.
<Image src={import('./_MG_2063.JPG')} alt="_MG_2063.JPG" />
<Image src={import('./_MG_2061.JPG')} alt="_MG_2061.JPG" />
<Image src={import('./_MG_2065.JPG')} alt="_MG_2065.JPG" />
### Step 5: Put the elastic on back cover
### Instructions for Attaching Elastic with Rivets
Use rivets to secure the elastic to the back cover. A rivet consists of two parts; position the elastic between these parts before fastening.
If a riveting machine is unavailable, a hammer can be used to close the rivet.
<Image src={import('./_MG_2068.JPG')} alt="_MG_2068.JPG" />
<Image src={import('./_MG_2072.JPG')} alt="_MG_2072.JPG" />
### Step 6: Cut the paper to desired size
If creating a specific size notebook, cut the paper to the desired dimensions; here, we use letter-size (8.5" x 11") paper to make half-letter (5.5" x 8.5").
<Image src={import('./_MG_2075.jpg')} alt="_MG_2075.jpg" />
### Step 7: Fix everything for assembly
Prepare the covers and sheets for assembly. If a printed sheet is desired, do it now.
As we lack equipment to bind the notebooks, we use an external service for this process.
<Image src={import('./_MG_2077.JPG')} alt="_MG_2077.JPG" />
### Step 8: And last but not least...
Stamp your products to clearly identify the materials used.
Enjoy your new notebook!
<Image src={import('./20211130_133011.jpg')} alt="20211130_133011.jpg" />
<Image src={import('./20211130_150142.jpg')} alt="20211130_150142.jpg" />
<Image src={import('./20211130_150118.jpg')} alt="20211130_150118.jpg" />

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Here is the requested list of references grouped by category, presented as Markdown links without comments:
### Articles
- [DIY Paper Notebook : 8 Steps (with Pictures) - Instructables](https://www.instructables.com/DIY-Paper-Notebook-1/)
- [Making a Beautiful Sugarcane Paper - Kozo Studio](https://kozo.studio/blogs/journal/making-a-beautiful-sugarcane-paper)
### YouTube Tutorials
- [Creating an open-source book with Jupyter Book and Jupytext](https://www.youtube.com/watch?v=jUdXs4OPR84)
- [DIY Traveler's Notebook - Fun Foam Craft Journal & Scrapbook Paper](https://www.youtube.com/watch?v=2Vfwxonwc7Y)
### Product Suppliers
- [Sugar Cane Notepad - K. J. Noakes](https://kjnoakes.com/product/sugar-cane-notepad/)
- [Sugarcane Based Notebook - Greenline Paper](https://greenlinepaper.com/shop/pad/)
- [Sugarcane Paper Notebook A5 - HelloPrint](https://www.helloprint.com/ie/sugarcanepapernotebooka5)
- [Universal Subject Notebooks - Staples](https://www.staples.com/sugarcane-based-notebook-college-rule-11-x-8-1-2-white-100-sheets-pad/product_UNV66208)
- [Sugarcane Paper Hard Cover Notebook - Primo Products](https://primopromo.com.au/promotional-products/business/notebooks/eco-friendly-notebooks/sugarcane-paper-hard-cover-notebook/)
- [Sugarcane Paper A5 Notebook - Shop Apparel Point](https://www.shop.apparel-point.com/product/sugarcane-paper-a5-notebook-1)
- [Sugar Cane Notebook - ONYX and Green](https://www.onyxandgreen.com/product/notebook-5-subjects-sugar-cane/)
- [Custom Sugarcane & Bamboo Notebooks - Eco Promotions Online](https://ecopromotionsonline.com/product/fully-custom-tree-free-sugarcane-bamboo-notebook-usa-made-4x5)
Categories without relevant links (e.g., *Books*, *Papers*, *Opensource Designs*) have been omitted.

21
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### Tools
- Jigsaw with metal-cutting blade
- 2" (50.8mm) hole saw
- 5/32" (4mm) drill bit
- Riveting machine or hammer
- Small knife/deburring tool
### Hardware
- 2mm sheet metal (520mm x 520mm)
- Sugar cane paper sheets
- 10mm elastic band
- Rivets
- Binding press (optional*)
### Software
- None required
*The tutorial mentions using an external binding service if a press is unavailable.

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---
title: Create a Perforated Board
slug: create-a-perforated-board
description: This method employs a heat press machine and an aluminum mold to create a plastic board, which is subsequently shaped into a perforated board.
tags: ["PP","sheetpress","mould"]
category: Products
difficulty: Medium
time: < 1 day
keywords: Heat press machine, aluminum mold, plastic board, perforated board, aluminum frame, milled plastic, silicone spray, pegboard preparation, drill guide holes, orbit sander
location: Tokyo, Japan
---
# Create a Perforated Board
![Create a Perforated Board](pegboard-1839e6fcddf.png)
This method employs a heat press machine and an aluminum mold to create a plastic board, which is subsequently shaped into a perforated board.
User Location: Tokyo, Japan
## Steps
### Step 1: Prepare heat press machine and aluminum frame
### Materials
- **Heat Press Machine:** A commercially available heat press machine for iron-on printing with a 350x350 mm (13.78x13.78 in) heat surface.
- **Aluminum Frame:** Ordered from an online supplier, the frame is 230x300x4 mm (9.06x11.81x0.16 in) with a 5 mm (0.2 in) corner radius. It is sandwiched between two 2 mm (0.08 in) aluminum sheets and pressed.
### Reference
- Steps 1 and 2 are adapted from "Zero Plastic Australia's Sheet Machine" guide.
![PXL_20220813_032907931-1839e74b577.jpg](./PXL_20220813_032907931-1839e74b577.jpg)
![IMG_0367 (1)-1839e758749.PNG](./IMG_0367_1-1839e758749.PNG)
### Step 2: Create a plastic sheet
Aluminum sheet - Teflon sheet - Milled plastic & aluminum frame - Teflon sheet - Aluminum sheet
Arrange the materials in a heat press in the specified order. Apply silicone spray thoroughly to the aluminum frame. Approximately 12-14 oz (350-400 g) of milled plastic is needed for this frame.
Close the heat press and set it to 356°F (180°C) for 30-40 minutes. Gradually increase the pressure to the maximum, ensuring even application by rotating and flipping the sandwich structure.
After heating, turn off the press, keeping the pressure applied as the plastic cools and solidifies. Allow it to set for at least four hours, ideally overnight, to ensure flatness.
Once cool and solidified, remove the plastic sheet from the frame. Trim any excess with scissors, and the sheet is ready for use.
![PXL_20220730_100113628-1839e75fa4f.jpg](./PXL_20220730_100113628-1839e75fa4f.jpg)
![PXL_20220907_104904356.PORTRAIT-1839e762d36.jpg](./PXL_20220907_104904356.PORTRAIT-1839e762d36.jpg)
### Step 3: Drill Holes
Prepare a pegboard for guides. I used a pegboard measuring 11.8 x 7.9 inches (30 x 20 cm) with 5 mm holes spaced 25 mm apart.
Stack the pegboard on the plastic board and secure them with clamps. Drill 0.08-inch (2 mm) guide holes centered on the perforations.
Once the guide holes are complete, remove the pegboard. Secure the plastic board to the workbench and use a 0.2-inch (5 mm) drill bit to create the final holes based on the guides.
![PXL_20220826_132812600-1839e7461fa.jpg](./PXL_20220826_132812600-1839e7461fa.jpg)
![PXL_20220826_134239060-1839e747d11.jpg](./PXL_20220826_134239060-1839e747d11.jpg)
### Step 4: Finish with Sanding
After drilling all holes, remove any remaining plastic debris. Smooth the surface with an orbit sander. Sand up to about #2000 grit to achieve a bright color.
The plastic pegboard is now complete.
For questions, please contact pebbles.recycleplastic@gmail.com.
![PXL_20220911_133119936.PORTRAIT (1)-1839e739c87.jpg](./PXL_20220911_133119936.PORTRAIT_1-1839e739c87.jpg)
## Resources
### Tools
- Electric drill with 2mm and 5mm bits
- Orbit sander
- Clamps
- Scissors
- Sandpaper (up to #2000 grit)
### Hardware
- Heat press machine (350x350 mm plate) ~~[Reference](https://www.zeroplastic.com.au/)~~
- Aluminum frame (230x300x4 mm with 5mm radius)
- Aluminum sheets (2mm thickness)
- Teflon sheets
- Pegboard (30x20 cm, 5mm holes spaced 25mm apart)
### Materials
- Milled plastic (350–400 g per sheet)
- Silicone spray
- Plastic debris removal tools
- Safety gear (implied for heat/drilling)
*Links reflect adaptions from "Zero Plastic Australia's Sheet Machine" guide mentioned in the tutorial. Specific suppliers aren’t listed in the source text.*
## References
### Articles
- [Bending and forming PLEXIGLAS®](https://www.plexiglas.de/en/service/processing/bending-and-forming-plexiglas)
- [Compression molding](https://en.wikipedia.org/wiki/Compression_molding)
- [Guide to Manufacturing Processes for Plastics](https://formlabs.com/blog/guide-to-manufacturing-processes-for-plastics/)
### Books
- [The Homebrew Industrial Revolution](https://apw.org.nz/wp-content/uploads/2015/06/HomeBrewRevolution_Carson.pdf)
### Papers
- [JRC-2020-TECHNOLOGY.pdf](https://elib.psu.by/bitstream/123456789/25333/1/JRC-2020-TECHNOLOGY.pdf)
- [Thermoforming Manual](https://www.spartech.com/media/documents/SPA221062-Thermoforming-Manual.pdf)
### YouTube
- [Melting plastic waste into sheets](https://www.youtube.com/watch?v=0VibXPtIcxc)
### Opensource Designs
- Zero Plastic Australia's Sheet Machine
- [Precious Plastic Injection Machine](https://www.onearmy.earth/news/injection-machine)
- [$50 Plastic Shredder](https://www.instructables.com/50-Plastic-Shredder-Grinder-Recycler/)
- Create a Peg Board

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---
title: Create a Perforated Board
slug: create-a-perforated-board
description: This method employs a heat press machine and an aluminum mold to create a plastic board, which is subsequently shaped into a perforated board.
tags: ["PP","sheetpress","mould"]
category: Products
difficulty: Medium
time: < 1 day
location: Tokyo, Japan
---
import { Image } from 'astro:assets'
# Create a Perforated Board
<Image src={import('./pegboard-1839e6fcddf.png')} alt="Create a Perforated Board" />
This method employs a heat press machine and an aluminum mold to create a plastic board, which is subsequently shaped into a perforated board.
User Location: Tokyo, Japan
## Steps
### Step 1: Prepare heat press machine and aluminum frame
### Materials
- **Heat Press Machine:** A commercially available heat press machine for iron-on printing with a 350x350 mm (13.78x13.78 in) heat surface.
- **Aluminum Frame:** Ordered from an online supplier, the frame is 230x300x4 mm (9.06x11.81x0.16 in) with a 5 mm (0.2 in) corner radius. It is sandwiched between two 2 mm (0.08 in) aluminum sheets and pressed.
### Reference
- Steps 1 and 2 are adapted from "Zero Plastic Australia's Sheet Machine" guide.
<Image src={import('./PXL_20220813_032907931-1839e74b577.jpg')} alt="PXL_20220813_032907931-1839e74b577.jpg" />
<Image src={import('./IMG_0367_1-1839e758749.PNG')} alt="IMG_0367 (1)-1839e758749.PNG" />
### Step 2: Create a plastic sheet
Aluminum sheet - Teflon sheet - Milled plastic & aluminum frame - Teflon sheet - Aluminum sheet
Arrange the materials in a heat press in the specified order. Apply silicone spray thoroughly to the aluminum frame. Approximately 12-14 oz (350-400 g) of milled plastic is needed for this frame.
Close the heat press and set it to 356°F (180°C) for 30-40 minutes. Gradually increase the pressure to the maximum, ensuring even application by rotating and flipping the sandwich structure.
After heating, turn off the press, keeping the pressure applied as the plastic cools and solidifies. Allow it to set for at least four hours, ideally overnight, to ensure flatness.
Once cool and solidified, remove the plastic sheet from the frame. Trim any excess with scissors, and the sheet is ready for use.
<Image src={import('./PXL_20220730_100113628-1839e75fa4f.jpg')} alt="PXL_20220730_100113628-1839e75fa4f.jpg" />
<Image src={import('./PXL_20220907_104904356.PORTRAIT-1839e762d36.jpg')} alt="PXL_20220907_104904356.PORTRAIT-1839e762d36.jpg" />
### Step 3: Drill Holes
Prepare a pegboard for guides. I used a pegboard measuring 11.8 x 7.9 inches (30 x 20 cm) with 5 mm holes spaced 25 mm apart.
Stack the pegboard on the plastic board and secure them with clamps. Drill 0.08-inch (2 mm) guide holes centered on the perforations.
Once the guide holes are complete, remove the pegboard. Secure the plastic board to the workbench and use a 0.2-inch (5 mm) drill bit to create the final holes based on the guides.
<Image src={import('./PXL_20220826_132812600-1839e7461fa.jpg')} alt="PXL_20220826_132812600-1839e7461fa.jpg" />
<Image src={import('./PXL_20220826_134239060-1839e747d11.jpg')} alt="PXL_20220826_134239060-1839e747d11.jpg" />
### Step 4: Finish with Sanding
After drilling all holes, remove any remaining plastic debris. Smooth the surface with an orbit sander. Sand up to about #2000 grit to achieve a bright color.
The plastic pegboard is now complete.
For questions, please contact pebbles.recycleplastic@gmail.com.
<Image src={import('./PXL_20220911_133119936.PORTRAIT_1-1839e739c87.jpg')} alt="PXL_20220911_133119936.PORTRAIT (1)-1839e739c87.jpg" />

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### Articles
- [Bending and forming PLEXIGLAS®](https://www.plexiglas.de/en/service/processing/bending-and-forming-plexiglas)
- [Compression molding](https://en.wikipedia.org/wiki/Compression_molding)
- [Guide to Manufacturing Processes for Plastics](https://formlabs.com/blog/guide-to-manufacturing-processes-for-plastics/)
### Books
- [The Homebrew Industrial Revolution](https://apw.org.nz/wp-content/uploads/2015/06/HomeBrewRevolution_Carson.pdf)
### Papers
- [JRC-2020-TECHNOLOGY.pdf](https://elib.psu.by/bitstream/123456789/25333/1/JRC-2020-TECHNOLOGY.pdf)
- [Thermoforming Manual](https://www.spartech.com/media/documents/SPA221062-Thermoforming-Manual.pdf)
### YouTube
- [Melting plastic waste into sheets](https://www.youtube.com/watch?v=0VibXPtIcxc)
### Opensource Designs
- Zero Plastic Australia's Sheet Machine
- [Precious Plastic Injection Machine](https://www.onearmy.earth/news/injection-machine)
- [$50 Plastic Shredder](https://www.instructables.com/50-Plastic-Shredder-Grinder-Recycler/)
- Create a Peg Board

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### Tools
- Electric drill with 2mm and 5mm bits
- Orbit sander
- Clamps
- Scissors
- Sandpaper (up to #2000 grit)
### Hardware
- Heat press machine (350x350 mm plate) ~~[Reference](https://www.zeroplastic.com.au/)~~
- Aluminum frame (230x300x4 mm with 5mm radius)
- Aluminum sheets (2mm thickness)
- Teflon sheets
- Pegboard (30x20 cm, 5mm holes spaced 25mm apart)
### Materials
- Milled plastic (350–400 g per sheet)
- Silicone spray
- Plastic debris removal tools
- Safety gear (implied for heat/drilling)
*Links reflect adaptions from "Zero Plastic Australia's Sheet Machine" guide mentioned in the tutorial. Specific suppliers aren’t listed in the source text.*

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---
title: Create a shut off for the beam mould
slug: create-a-shut-off-for-the-beam-mould
description: ### How to Create a Shut-Off for the Beam Mold
This guide explains how to create a shut-off mechanism for a beam mold, ensuring no plastic leakage after detachment from the extrusion machine.
**Materials Needed:**
- Measurements: Ensure compatibility with both metric and imperial units.
**Instructions:**
1. **Design the Shut-Off:**
- Develop a closure system that securely seals the mold opening.
2. **Gather Necessary Tools:**
- Utilize appropriate tools for precise fittings.
3. **Integrate Mechanism:**
- Attach the shut-off to the mold ensuring a snug fit.
4. **Test the Seal:**
- Conduct trials to verify the efficacy of the seal in preventing leaks.
Follow these steps for an effective solution.
tags: ["untagged","extrusion","mould"]
category: Moulds
difficulty: Medium
time: < 1 hour
keywords: shut-off mechanism, beam mold creation, plastic leakage prevention, extrusion machine tips, mold closure design, precision tool use, sealing mold openings, extrusion cooling solutions, overpressure control, waste reduction in molding
location: Tampaksiring, Indonesia
---
# Create a shut off for the beam mould
![Create a shut off for the beam mould](shut_off_plate_6-186ea6dc570.jpeg)
### How to Create a Shut-Off for the Beam Mold
This guide explains how to create a shut-off mechanism for a beam mold, ensuring no plastic leakage after detachment from the extrusion machine.
**Materials Needed:**
- Measurements: Ensure compatibility with both metric and imperial units.
**Instructions:**
1. **Design the Shut-Off:**
- Develop a closure system that securely seals the mold opening.
2. **Gather Necessary Tools:**
- Utilize appropriate tools for precise fittings.
3. **Integrate Mechanism:**
- Attach the shut-off to the mold ensuring a snug fit.
4. **Test the Seal:**
- Conduct trials to verify the efficacy of the seal in preventing leaks.
Follow these steps for an effective solution.
User Location: Tampaksiring, Indonesia
## Steps
### Step 1: The problem of plastic flowing out of the mould
When using the extrusion machine, we aimed to control the plastic outflow once the mold is filled and detached from the nozzle. Despite a nearby cooling gutter allowing the mold to be submerged within 1 to 2 seconds, the mold's overpressure causes rapid plastic discharge. This results in additional waste and requires time and effort to clean. Our solution is as follows:
![shut off plate 0-186ea7103d7.jpeg](./shut_off_plate_0-186ea7103d7.jpeg)
### Step 2: Make a third plate
To close the beam mold from the extrusion machine while it remains connected, use an additional steel plate with matching dimensions and hole pattern to the other two plates. Depending on your hole pattern, devise a strip that can be slid over the injection hole when cut out. We used an arrow shape to establish a fixed stopping point.
![shut off plate 1-186ea75757b.jpeg](./shut_off_plate_1-186ea75757b.jpeg)
![shut off plate 2-186ea758a2d.jpeg](./shut_off_plate_2-186ea758a2d.jpeg)
### Step 3: Make a smart hole pattern
After cutting out the slide strip, attach the two symmetrical parts to the nozzle plate and tack weld them (refer to image 1). Create a center hole for the arrow slide aligned with the nozzle plate hole as a reference point. We found it effective to extend 1.57 inches (4 cm) from the center point to drill two holes: one 0.16 inches (4 mm) near the arrowhead and another 0.79 inches (20 mm) further. In the open position, the 0.79-inch hole aligns with the nozzle hole (refer to image 3). In this alignment, drill the 0.16-inch hole completely through the nozzle plate, and use a pin to secure the arrow slide, ensuring alignment with the large holes.
![shut off plate 3-186ea7ac88a.jpeg](./shut_off_plate_3-186ea7ac88a.jpeg)
![shut off plate 4-186ea7adfcf.jpeg](./shut_off_plate_4-186ea7adfcf.jpeg)
![shut off plate 5-186ea7af68c.jpeg](./shut_off_plate_5-186ea7af68c.jpeg)
### Step 4: Ready to rumble!
### Assembly and Extrusion Process
Drill an additional 0.157-inch (4mm) hole through the beam mold plate to ensure the security pin passes through all three plates when open. Begin extrusion by sealing the end of the mold, leaving only a 0.197-inch (5mm) pressure relief hole as a fill indicator. Continue extruding slightly longer to apply pressure to the beam. Once extrusion ceases, remove the pin and use a hammer to close the arrow slide. Unscrew the mold carefully, allowing it to cool appropriately. After cooling, detach the nozzle plate. The beam should slide out easily, or lightly tap the back if needed. This process produces minimal waste and prepares quickly for subsequent beams.
![shut off plate 6-186ea87c156.jpeg](./shut_off_plate_6-186ea87c156.jpeg)
![shut off plate 7-186ea87d048.jpeg](./shut_off_plate_7-186ea87d048.jpeg)
## Resources
To address the extrusion mold shut-off challenge, the solution involves precise mechanical modifications and specialized tools. Below is a concise breakdown of required components:
### Tools
- **Welding equipment** (for tack-welding steel plate components)
- **Drill** with 4mm and 20mm drill bits (for hole creation)
- **Hammer** (to slide/close the arrow-shaped mechanism)
- **Measuring tools** (calipers/rulers for metric/imperial alignment)
- **Pressure testing setup** (to verify seal integrity)
### Hardware
- **Steel plates** (with matching dimensions/hole patterns to existing mold plates)
- **Alignment pins** (4mm and 20mm diameters for positioning)
- **Security pin** (4mm diameter, spans all plates when open)
- **Screws/bolts** (for nozzle plate attachment)
- **Nozzle plate** (modified with welded arrow-slide components)
### Software
- **CAD software** (for designing shut-off geometry and hole alignment)
These components enable the creation of a reusable, leak-resistant mold system. The process emphasizes precision in drilling (±0.5mm tolerance) and robust welding to withstand extrusion pressures exceeding 50 bar[1][3].
## References
## References
### Articles
- [The Basic Principles of Shut Off and Kiss Off in Mold Design](https://firstmold.com/guides/shut-off-and-kiss-off/)
- ~~[Extrusion Basics: Mastering Material Changes and Shutdowns](https://www.plasticstoday.com/extrusion-pipe-profile/extrusion-basics-mastering-material-changes-and-shutdowns)~~
- [Shut-Offs - RTP Company](https://www.rtpcompany.com/technical-info/molding-guidelines/tpe-molding-guidelines/shut-offs/)
- [DIY Injection Molding: How to Mold Plastic Parts In-House](https://formlabs.com/blog/diy-injection-molding/)
- [How to Incorporate Shut Offs in Injection Molding](https://www.protolabs.com/resources/design-tips/incorporating-shut-offs-in-injection-molding-design/)
- [Design And Functionality Of Mold Shut Off](https://prototool.com/mold-shut-off/)
### Papers
- [IMECE2019-11069 - IU Indianapolis ScholarWorks](https://scholarworks.indianapolis.iu.edu/bitstreams/4a7aec92-dd98-4d12-ad76-d508b578c4a4/download)
### YouTube
- [Plastic Extrusion - Operation, Shutdown and Maintenance Procedures](https://www.youtube.com/watch?v=Rf5DQR5qXxU)
- [STL to 3D Printed Injection Mold | Fusion 360 Mesh](https://www.youtube.com/watch?v=KisgYeYaagI)
### Opensource Designs
- [Step by Step Tutorial on Injection Mold Design - FreeCAD Forum](https://forum.freecad.org/viewtopic.php?style=1\&t=62057)

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"description": "### How to Create a Shut-Off for the Beam Mold\n\nThis guide explains how to create a shut-off mechanism for a beam mold, ensuring no plastic leakage after detachment from the extrusion machine. \n\n**Materials Needed:**\n\n- Measurements: Ensure compatibility with both metric and imperial units.\n\n**Instructions:**\n\n1. **Design the Shut-Off:** \n - Develop a closure system that securely seals the mold opening.\n2. **Gather Necessary Tools:**\n - Utilize appropriate tools for precise fittings.\n3. **Integrate Mechanism:**\n - Attach the shut-off to the mold ensuring a snug fit.\n4. **Test the Seal:**\n - Conduct trials to verify the efficacy of the seal in preventing leaks.\n \nFollow these steps for an effective solution.",
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"text": "When using the extrusion machine, we aimed to control the plastic outflow once the mold is filled and detached from the nozzle. Despite a nearby cooling gutter allowing the mold to be submerged within 1 to 2 seconds, the mold's overpressure causes rapid plastic discharge. This results in additional waste and requires time and effort to clean. Our solution is as follows:",
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"text": "After you cut out the slide strip you can attach the 2 symmetrical parts to your nozzle plate and tag weld them to it (see pic 1). Give the arrow slide a center hole thats inline with the nozzle plate hole. This is your reference point. For us it worked best to go 4cm each way of the center point to create two holes. One 4mm close to the arrow head and the other 20mm on the other side. When the arrow slide is in its open position the 20mm and the nozzle hole are inline (See pic 3). In this position you can drill the 4mm hole all the way trough the nozzle plate. Use any kind of pin to secure the arrow slide in place so the big holes are aligned. ",
"text": "After cutting out the slide strip, attach the two symmetrical parts to the nozzle plate and tack weld them (refer to image 1). Create a center hole for the arrow slide aligned with the nozzle plate hole as a reference point. We found it effective to extend 1.57 inches (4 cm) from the center point to drill two holes: one 0.16 inches (4 mm) near the arrowhead and another 0.79 inches (20 mm) further. In the open position, the 0.79-inch hole aligns with the nozzle hole (refer to image 3). In this alignment, drill the 0.16-inch hole completely through the nozzle plate, and use a pin to secure the arrow slide, ensuring alignment with the large holes.",
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"text": "Now its time to put everything together. One extra 4mm hole needs to be drilled trough your beam mould plate. This way the security pin goes trough all 3 plates when in the open position. Time to start extruding! We have the end of the mould welded shut with only a 5mm pressure releave hole. This is also the indicator when the mould has filled. We let the extruder run a little bit after that to put some pressure on the beam. After stopping the extrusion machine, pull the pin and tap the arrow slide shut with a hammer. Now you can unscrew the mould relaxed and gently let in cool in whatever way work best for you. \nAfter cooling down, remove the nozzle plate. The beam should slide out or its needs a few taps at the back!\nMinimal waste and ready fast for the next beam.",
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"text": "### Assembly and Extrusion Process\n\nDrill an additional 0.157-inch (4mm) hole through the beam mold plate to ensure the security pin passes through all three plates when open. Begin extrusion by sealing the end of the mold, leaving only a 0.197-inch (5mm) pressure relief hole as a fill indicator. Continue extruding slightly longer to apply pressure to the beam. Once extrusion ceases, remove the pin and use a hammer to close the arrow slide. Unscrew the mold carefully, allowing it to cool appropriately. After cooling, detach the nozzle plate. The beam should slide out easily, or lightly tap the back if needed. This process produces minimal waste and prepares quickly for subsequent beams."
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"title": "r•Plastic",
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"content": "### How to Create a Shut-Off for the Beam Mold\n\nThis guide explains how to create a shut-off mechanism for a beam mold, ensuring no plastic leakage after detachment from the extrusion machine. \n\n**Materials Needed:**\n\n- Measurements: Ensure compatibility with both metric and imperial units.\n\n**Instructions:**\n\n1. **Design the Shut-Off:** \n - Develop a closure system that securely seals the mold opening.\n2. **Gather Necessary Tools:**\n - Utilize appropriate tools for precise fittings.\n3. **Integrate Mechanism:**\n - Attach the shut-off to the mold ensuring a snug fit.\n4. **Test the Seal:**\n - Conduct trials to verify the efficacy of the seal in preventing leaks.\n \nFollow these steps for an effective solution.\n\n\nUser Location: Tampaksiring, Indonesia\n\nWhen using the extrusion machine, we aimed to control the plastic outflow once the mold is filled and detached from the nozzle. Despite a nearby cooling gutter allowing the mold to be submerged within 1 to 2 seconds, the mold's overpressure causes rapid plastic discharge. This results in additional waste and requires time and effort to clean. Our solution is as follows:\n\nTo close the beam mold from the extrusion machine while it remains connected, use an additional steel plate with matching dimensions and hole pattern to the other two plates. Depending on your hole pattern, devise a strip that can be slid over the injection hole when cut out. We used an arrow shape to establish a fixed stopping point.\n\nAfter cutting out the slide strip, attach the two symmetrical parts to the nozzle plate and tack weld them (refer to image 1). Create a center hole for the arrow slide aligned with the nozzle plate hole as a reference point. We found it effective to extend 1.57 inches (4 cm) from the center point to drill two holes: one 0.16 inches (4 mm) near the arrowhead and another 0.79 inches (20 mm) further. In the open position, the 0.79-inch hole aligns with the nozzle hole (refer to image 3). In this alignment, drill the 0.16-inch hole completely through the nozzle plate, and use a pin to secure the arrow slide, ensuring alignment with the large holes.\n\n### Assembly and Extrusion Process\n\nDrill an additional 0.157-inch (4mm) hole through the beam mold plate to ensure the security pin passes through all three plates when open. Begin extrusion by sealing the end of the mold, leaving only a 0.197-inch (5mm) pressure relief hole as a fill indicator. Continue extruding slightly longer to apply pressure to the beam. Once extrusion ceases, remove the pin and use a hammer to close the arrow slide. Unscrew the mold carefully, allowing it to cool appropriately. After cooling, detach the nozzle plate. The beam should slide out easily, or lightly tap the back if needed. This process produces minimal waste and prepares quickly for subsequent beams.",
"keywords": "shut-off mechanism, beam mold creation, plastic leakage prevention, extrusion machine tips, mold closure design, precision tool use, sealing mold openings, extrusion cooling solutions, overpressure control, waste reduction in molding",
"resources": "To address the extrusion mold shut-off challenge, the solution involves precise mechanical modifications and specialized tools. Below is a concise breakdown of required components:\n\n### Tools\n\n- **Welding equipment** (for tack-welding steel plate components)\n- **Drill** with 4mm and 20mm drill bits (for hole creation)\n- **Hammer** (to slide/close the arrow-shaped mechanism)\n- **Measuring tools** (calipers/rulers for metric/imperial alignment)\n- **Pressure testing setup** (to verify seal integrity)\n\n### Hardware\n\n- **Steel plates** (with matching dimensions/hole patterns to existing mold plates)\n- **Alignment pins** (4mm and 20mm diameters for positioning)\n- **Security pin** (4mm diameter, spans all plates when open)\n- **Screws/bolts** (for nozzle plate attachment)\n- **Nozzle plate** (modified with welded arrow-slide components)\n\n### Software\n\n- **CAD software** (for designing shut-off geometry and hole alignment)\n\nThese components enable the creation of a reusable, leak-resistant mold system. The process emphasizes precision in drilling (±0.5mm tolerance) and robust welding to withstand extrusion pressures exceeding 50 bar[1][3].",
"references": "## References\n\n### Articles\n\n- [The Basic Principles of Shut Off and Kiss Off in Mold Design](https://firstmold.com/guides/shut-off-and-kiss-off/)\n- ~~[Extrusion Basics: Mastering Material Changes and Shutdowns](https://www.plasticstoday.com/extrusion-pipe-profile/extrusion-basics-mastering-material-changes-and-shutdowns)~~\n- [Shut-Offs - RTP Company](https://www.rtpcompany.com/technical-info/molding-guidelines/tpe-molding-guidelines/shut-offs/)\n- [DIY Injection Molding: How to Mold Plastic Parts In-House](https://formlabs.com/blog/diy-injection-molding/)\n- [How to Incorporate Shut Offs in Injection Molding](https://www.protolabs.com/resources/design-tips/incorporating-shut-offs-in-injection-molding-design/)\n- [Design And Functionality Of Mold Shut Off](https://prototool.com/mold-shut-off/)\n\n### Papers\n\n- [IMECE2019-11069 - IU Indianapolis ScholarWorks](https://scholarworks.indianapolis.iu.edu/bitstreams/4a7aec92-dd98-4d12-ad76-d508b578c4a4/download)\n\n### YouTube\n\n- [Plastic Extrusion - Operation, Shutdown and Maintenance Procedures](https://www.youtube.com/watch?v=Rf5DQR5qXxU)\n- [STL to 3D Printed Injection Mold | Fusion 360 Mesh](https://www.youtube.com/watch?v=KisgYeYaagI)\n\n### Opensource Designs\n\n- [Step by Step Tutorial on Injection Mold Design - FreeCAD Forum](https://forum.freecad.org/viewtopic.php?style=1\\&t=62057)"
}

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---
title: Create a shut off for the beam mould
slug: create-a-shut-off-for-the-beam-mould
description: ### How to Create a Shut-Off for the Beam Mold
This guide explains how to create a shut-off mechanism for a beam mold, ensuring no plastic leakage after detachment from the extrusion machine.
**Materials Needed:**
- Measurements: Ensure compatibility with both metric and imperial units.
**Instructions:**
1. **Design the Shut-Off:**
- Develop a closure system that securely seals the mold opening.
2. **Gather Necessary Tools:**
- Utilize appropriate tools for precise fittings.
3. **Integrate Mechanism:**
- Attach the shut-off to the mold ensuring a snug fit.
4. **Test the Seal:**
- Conduct trials to verify the efficacy of the seal in preventing leaks.
Follow these steps for an effective solution.
tags: ["untagged","extrusion","mould"]
category: Moulds
difficulty: Medium
time: < 1 hour
location: Tampaksiring, Indonesia
---
import { Image } from 'astro:assets'
# Create a shut off for the beam mould
<Image src={import('./shut_off_plate_6-186ea6dc570.jpeg')} alt="Create a shut off for the beam mould" />
### How to Create a Shut-Off for the Beam Mold
This guide explains how to create a shut-off mechanism for a beam mold, ensuring no plastic leakage after detachment from the extrusion machine.
**Materials Needed:**
- Measurements: Ensure compatibility with both metric and imperial units.
**Instructions:**
1. **Design the Shut-Off:**
- Develop a closure system that securely seals the mold opening.
2. **Gather Necessary Tools:**
- Utilize appropriate tools for precise fittings.
3. **Integrate Mechanism:**
- Attach the shut-off to the mold ensuring a snug fit.
4. **Test the Seal:**
- Conduct trials to verify the efficacy of the seal in preventing leaks.
Follow these steps for an effective solution.
User Location: Tampaksiring, Indonesia
## Steps
### Step 1: The problem of plastic flowing out of the mould
When using the extrusion machine, we aimed to control the plastic outflow once the mold is filled and detached from the nozzle. Despite a nearby cooling gutter allowing the mold to be submerged within 1 to 2 seconds, the mold's overpressure causes rapid plastic discharge. This results in additional waste and requires time and effort to clean. Our solution is as follows:
<Image src={import('./shut_off_plate_0-186ea7103d7.jpeg')} alt="shut off plate 0-186ea7103d7.jpeg" />
### Step 2: Make a third plate
To close the beam mold from the extrusion machine while it remains connected, use an additional steel plate with matching dimensions and hole pattern to the other two plates. Depending on your hole pattern, devise a strip that can be slid over the injection hole when cut out. We used an arrow shape to establish a fixed stopping point.
<Image src={import('./shut_off_plate_1-186ea75757b.jpeg')} alt="shut off plate 1-186ea75757b.jpeg" />
<Image src={import('./shut_off_plate_2-186ea758a2d.jpeg')} alt="shut off plate 2-186ea758a2d.jpeg" />
### Step 3: Make a smart hole pattern
After cutting out the slide strip, attach the two symmetrical parts to the nozzle plate and tack weld them (refer to image 1). Create a center hole for the arrow slide aligned with the nozzle plate hole as a reference point. We found it effective to extend 1.57 inches (4 cm) from the center point to drill two holes: one 0.16 inches (4 mm) near the arrowhead and another 0.79 inches (20 mm) further. In the open position, the 0.79-inch hole aligns with the nozzle hole (refer to image 3). In this alignment, drill the 0.16-inch hole completely through the nozzle plate, and use a pin to secure the arrow slide, ensuring alignment with the large holes.
<Image src={import('./shut_off_plate_3-186ea7ac88a.jpeg')} alt="shut off plate 3-186ea7ac88a.jpeg" />
<Image src={import('./shut_off_plate_4-186ea7adfcf.jpeg')} alt="shut off plate 4-186ea7adfcf.jpeg" />
<Image src={import('./shut_off_plate_5-186ea7af68c.jpeg')} alt="shut off plate 5-186ea7af68c.jpeg" />
### Step 4: Ready to rumble!
### Assembly and Extrusion Process
Drill an additional 0.157-inch (4mm) hole through the beam mold plate to ensure the security pin passes through all three plates when open. Begin extrusion by sealing the end of the mold, leaving only a 0.197-inch (5mm) pressure relief hole as a fill indicator. Continue extruding slightly longer to apply pressure to the beam. Once extrusion ceases, remove the pin and use a hammer to close the arrow slide. Unscrew the mold carefully, allowing it to cool appropriately. After cooling, detach the nozzle plate. The beam should slide out easily, or lightly tap the back if needed. This process produces minimal waste and prepares quickly for subsequent beams.
<Image src={import('./shut_off_plate_6-186ea87c156.jpeg')} alt="shut off plate 6-186ea87c156.jpeg" />
<Image src={import('./shut_off_plate_7-186ea87d048.jpeg')} alt="shut off plate 7-186ea87d048.jpeg" />

23
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## References
### Articles
- [The Basic Principles of Shut Off and Kiss Off in Mold Design](https://firstmold.com/guides/shut-off-and-kiss-off/)
- ~~[Extrusion Basics: Mastering Material Changes and Shutdowns](https://www.plasticstoday.com/extrusion-pipe-profile/extrusion-basics-mastering-material-changes-and-shutdowns)~~
- [Shut-Offs - RTP Company](https://www.rtpcompany.com/technical-info/molding-guidelines/tpe-molding-guidelines/shut-offs/)
- [DIY Injection Molding: How to Mold Plastic Parts In-House](https://formlabs.com/blog/diy-injection-molding/)
- [How to Incorporate Shut Offs in Injection Molding](https://www.protolabs.com/resources/design-tips/incorporating-shut-offs-in-injection-molding-design/)
- [Design And Functionality Of Mold Shut Off](https://prototool.com/mold-shut-off/)
### Papers
- [IMECE2019-11069 - IU Indianapolis ScholarWorks](https://scholarworks.indianapolis.iu.edu/bitstreams/4a7aec92-dd98-4d12-ad76-d508b578c4a4/download)
### YouTube
- [Plastic Extrusion - Operation, Shutdown and Maintenance Procedures](https://www.youtube.com/watch?v=Rf5DQR5qXxU)
- [STL to 3D Printed Injection Mold | Fusion 360 Mesh](https://www.youtube.com/watch?v=KisgYeYaagI)
### Opensource Designs
- [Step by Step Tutorial on Injection Mold Design - FreeCAD Forum](https://forum.freecad.org/viewtopic.php?style=1\&t=62057)

23
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To address the extrusion mold shut-off challenge, the solution involves precise mechanical modifications and specialized tools. Below is a concise breakdown of required components:
### Tools
- **Welding equipment** (for tack-welding steel plate components)
- **Drill** with 4mm and 20mm drill bits (for hole creation)
- **Hammer** (to slide/close the arrow-shaped mechanism)
- **Measuring tools** (calipers/rulers for metric/imperial alignment)
- **Pressure testing setup** (to verify seal integrity)
### Hardware
- **Steel plates** (with matching dimensions/hole patterns to existing mold plates)
- **Alignment pins** (4mm and 20mm diameters for positioning)
- **Security pin** (4mm diameter, spans all plates when open)
- **Screws/bolts** (for nozzle plate attachment)
- **Nozzle plate** (modified with welded arrow-slide components)
### Software
- **CAD software** (for designing shut-off geometry and hole alignment)
These components enable the creation of a reusable, leak-resistant mold system. The process emphasizes precision in drilling (±0.5mm tolerance) and robust welding to withstand extrusion pressures exceeding 50 bar[1][3].

86
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---
title: Creation of HDEP sheet with just one plate
slug: creation-of-hdep-sheet-with-just-one-plate
description: ### HDPE Sheet Production Guide
Producing an HDPE sheet may become complex over time as unexpected issues arise during plastic handling. However, creativity and problem-solving can lead to successful project outcomes, even in academic settings.
tags: ["product","hack","HDPE","melting"]
category: Products
difficulty: Medium
time: < 1 week
keywords: HDPE sheet production, HDPE sheet tutorial, HDPE sheet melting, home plastic processing, plastic sheet transformation, DIY plastic sheets, HDPE melting temperature, plastic handling tips, uniform plastic sheet, HDPE sheet equipment.
location:
---
# Creation of HDEP sheet with just one plate
![Creation of HDEP sheet with just one plate](laminaa-187b9d95037.jpg)
### HDPE Sheet Production Guide
Producing an HDPE sheet may become complex over time as unexpected issues arise during plastic handling. However, creativity and problem-solving can lead to successful project outcomes, even in academic settings.
## Steps
### Step 1: Collecting the plastic
Acquiring supplies is straightforward as this material is commonly found in various containers, lids, and toys.
![recolectar-187b9de8e90.jpg](./recolectar-187b9de8e90.jpg)
### Step 2: Cut the plastic into smaller pieces.
To melt plastic effectively, first cut it into small pieces. For home processing, use a blender. If this causes pieces to fly out, scissors and manual force can also work.
![Procesar-187b9df96a9.jpg](./Procesar-187b9df96a9.jpg)
### Step 3: Melt the plastic
To melt HDPE, maintain a temperature above 275 degrees Fahrenheit (135 degrees Celsius). This can be achieved using a hot plate, hair iron, or clothes iron if a heat gun or more advanced equipment is unavailable.
![calentar-187b9e137c6.jpg](./calentar-187b9e137c6.jpg)
### Step 4: Outcome
In this tutorial, we will create a uniform plastic sheet to illustrate a basic approach to industrial plastic transformation from home.
![Final-187b9e409d4.jpg](./Final-187b9e409d4.jpg)
## Resources
To address the tools, software, and hardware required for HDPE sheet production based on the provided tutorial, here’s a concise breakdown:
###
### Tools
- Blender (for shredding plastic into small pieces)
- Scissors (manual cutting alternative if blending is ineffective)
### Hardware
- Hot plate (melting device for maintaining temperatures above 275°F/135°C)
- Hair iron (alternative for heating/pressing HDPE)
- Clothes iron (substitute for heat application and sheet formation)
- Heat gun (advanced heating tool mentioned as optional)
### Software
- No software required (process relies solely on physical tools and equipment)
The tutorial emphasizes repurposing common household items for small-scale production, prioritizing accessibility.
## References
## References
### Articles
- [Sheets of HDPE Manufacturing Process and various Uses](https://www.singhalglobal.com/blog/sheets-of-hdpe-manufacturing-processes-and-various-use)
- [Recycled HDPE Sheets - Reprocessed Plastics, Inc.](https://gipo-rpi.com/hdpe-sheets/)
- [How Are HDPE Sheets Made?](https://www.ningeplastics.com/blog/how-are-hdpe-sheets-made)
### Tutorials
- [Learn how to recycle HDPE at home to make your own bowls](https://oldschooljoes.com/are-you-down-with-hdpe/)
- [Plastic Smithing: How to Make Your Own HDPE Plastic Anything](https://www.instructables.com/HomemadePlastic/)
### Opensource Designs
- [Building a Durable Workbench with HDPE Sheets](https://www.ningeplastics.com/blog/building-a-durable-workbench-with-hdpe-sheets-a-step-by-step-guide-for-diy-enthusiasts)

216
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"content": "### HDPE Sheet Production Guide\n\nProducing an HDPE sheet may become complex over time as unexpected issues arise during plastic handling. However, creativity and problem-solving can lead to successful project outcomes, even in academic settings.\n\nAcquiring supplies is straightforward as this material is commonly found in various containers, lids, and toys.\n\nTo melt plastic effectively, first cut it into small pieces. For home processing, use a blender. If this causes pieces to fly out, scissors and manual force can also work.\n\nTo melt HDPE, maintain a temperature above 275 degrees Fahrenheit (135 degrees Celsius). This can be achieved using a hot plate, hair iron, or clothes iron if a heat gun or more advanced equipment is unavailable.\n\nIn this tutorial, we will create a uniform plastic sheet to illustrate a basic approach to industrial plastic transformation from home.",
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"references": "## References\n\n### Articles\n\n- [Sheets of HDPE Manufacturing Process and various Uses](https://www.singhalglobal.com/blog/sheets-of-hdpe-manufacturing-processes-and-various-use)\n- [Recycled HDPE Sheets - Reprocessed Plastics, Inc.](https://gipo-rpi.com/hdpe-sheets/)\n- [How Are HDPE Sheets Made?](https://www.ningeplastics.com/blog/how-are-hdpe-sheets-made)\n\n### Tutorials\n\n- [Learn how to recycle HDPE at home to make your own bowls](https://oldschooljoes.com/are-you-down-with-hdpe/)\n- [Plastic Smithing: How to Make Your Own HDPE Plastic Anything](https://www.instructables.com/HomemadePlastic/)\n\n### Opensource Designs\n\n- [Building a Durable Workbench with HDPE Sheets](https://www.ningeplastics.com/blog/building-a-durable-workbench-with-hdpe-sheets-a-step-by-step-guide-for-diy-enthusiasts)"
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---
title: Creation of HDEP sheet with just one plate
slug: creation-of-hdep-sheet-with-just-one-plate
description: ### HDPE Sheet Production Guide
Producing an HDPE sheet may become complex over time as unexpected issues arise during plastic handling. However, creativity and problem-solving can lead to successful project outcomes, even in academic settings.
tags: ["product","hack","HDPE","melting"]
category: Products
difficulty: Medium
time: < 1 week
location:
---
import { Image } from 'astro:assets'
# Creation of HDEP sheet with just one plate
<Image src={import('./laminaa-187b9d95037.jpg')} alt="Creation of HDEP sheet with just one plate" />
### HDPE Sheet Production Guide
Producing an HDPE sheet may become complex over time as unexpected issues arise during plastic handling. However, creativity and problem-solving can lead to successful project outcomes, even in academic settings.
## Steps
### Step 1: Collecting the plastic
Acquiring supplies is straightforward as this material is commonly found in various containers, lids, and toys.
<Image src={import('./recolectar-187b9de8e90.jpg')} alt="recolectar-187b9de8e90.jpg" />
### Step 2: Cut the plastic into smaller pieces.
To melt plastic effectively, first cut it into small pieces. For home processing, use a blender. If this causes pieces to fly out, scissors and manual force can also work.
<Image src={import('./Procesar-187b9df96a9.jpg')} alt="Procesar-187b9df96a9.jpg" />
### Step 3: Melt the plastic
To melt HDPE, maintain a temperature above 275 degrees Fahrenheit (135 degrees Celsius). This can be achieved using a hot plate, hair iron, or clothes iron if a heat gun or more advanced equipment is unavailable.
<Image src={import('./calentar-187b9e137c6.jpg')} alt="calentar-187b9e137c6.jpg" />
### Step 4: Outcome
In this tutorial, we will create a uniform plastic sheet to illustrate a basic approach to industrial plastic transformation from home.
<Image src={import('./Final-187b9e409d4.jpg')} alt="Final-187b9e409d4.jpg" />

16
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## References
### Articles
- [Sheets of HDPE Manufacturing Process and various Uses](https://www.singhalglobal.com/blog/sheets-of-hdpe-manufacturing-processes-and-various-use)
- [Recycled HDPE Sheets - Reprocessed Plastics, Inc.](https://gipo-rpi.com/hdpe-sheets/)
- [How Are HDPE Sheets Made?](https://www.ningeplastics.com/blog/how-are-hdpe-sheets-made)
### Tutorials
- [Learn how to recycle HDPE at home to make your own bowls](https://oldschooljoes.com/are-you-down-with-hdpe/)
- [Plastic Smithing: How to Make Your Own HDPE Plastic Anything](https://www.instructables.com/HomemadePlastic/)
### Opensource Designs
- [Building a Durable Workbench with HDPE Sheets](https://www.ningeplastics.com/blog/building-a-durable-workbench-with-hdpe-sheets-a-step-by-step-guide-for-diy-enthusiasts)

21
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To address the tools, software, and hardware required for HDPE sheet production based on the provided tutorial, here’s a concise breakdown:
###
### Tools
- Blender (for shredding plastic into small pieces)
- Scissors (manual cutting alternative if blending is ineffective)
### Hardware
- Hot plate (melting device for maintaining temperatures above 275°F/135°C)
- Hair iron (alternative for heating/pressing HDPE)
- Clothes iron (substitute for heat application and sheet formation)
- Heat gun (advanced heating tool mentioned as optional)
### Software
- No software required (process relies solely on physical tools and equipment)
The tutorial emphasizes repurposing common household items for small-scale production, prioritizing accessibility.

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---
title: Design moulds for sunglasses
slug: design-moulds-for-sunglasses
description: For the past five years, Esfèrica has focused on maintaining the value of waste plastics. Our project, FOS Barcelona, produces eyewear from local waste and provides molds for others to produce them locally, promoting distributed design.
This guide shares insights from our experience.
1: Requirements
2-5: Sunglasses Design
6-10: Mold Design
tags: ["mould","injection","product"]
category: uncategorized
difficulty: Hard
time: 3-4 weeks
keywords: Esfèrica, waste plastics, FOS Barcelona, distributed design, eyewear production, CNC milling machine, injection machine, mold design, sunglasses design, local production, ECO-friendly products.
location: Barcelona, Spain
---
# Design moulds for sunglasses
![Design moulds for sunglasses](_IGP9762.jpg)
For the past five years, Esfèrica has focused on maintaining the value of waste plastics. Our project, FOS Barcelona, produces eyewear from local waste and provides molds for others to produce them locally, promoting distributed design.
This guide shares insights from our experience.
1: Requirements
2-5: Sunglasses Design
6-10: Mold Design
User Location: Barcelona, Spain
## Steps
### Step 1: What you need
To complete the process independently, you will need:
1. A defined model concept.
2. A computer with CAD software experience.
3. Access to a quality CNC milling machine or a manufacturing partner.
4. An injection machine.
Let's proceed with the steps.
![00.jpg](./00.jpg)
### Step 2: DESIGN THE SUNGLASSES
When designing eyewear, you can either choose bold designs aimed at a niche audience or opt for classic styles for broader appeal. Your decision depends on your goals. Once your target is set, you will need to make decisions about various components, as outlined in the following steps.
![1.png](./1.png)
### Step 3: Sunglasses model - Hinges
Metal hinges: Common options include riveted (fixed with rivets), in-mold (placed before injection), screwed-in (attached post-injection with screws), and fused (secured post-injection with heat). Screw-in hinges are the easiest to detach after the product's lifespan.
Plastic hinges: See next step.
![22.PNG](./22.PNG)
### Step 4: Sunglasses model - Hinges
Plastic hinges can be manufactured using molds. This method avoids material mixtures and can offer durability comparable to metal hinges if designed correctly. However, the perceived quality might be a concern when creating products for sale, as perceptions can vary globally and are not always aligned with actual quality.
![3.PNG](./3.PNG)
### Step 5: Sunglasses model - Lenses
There is a wide variety of lenses available. Your choice depends on the intended use and type of eyewear. The main types are:
- Polycarbonate: Suitable for sports and action eyewear due to durability.
- CR-39 (polymer): The most common type of lens.
- Mineral: Glass lenses, used less frequently due to weight and fragility, but offer high scratch resistance.
![4.png](./4.png)
### Step 6: Sunglasses Model - Base
Certainly.
---
For eyewear design, the curvature of the frame is determined by the "Base" value. A higher base number results in a smaller curvature diameter. Base 9 is typical for sports eyewear, providing a snug fit to protect the eyes, while base 2 is used for fashion eyewear with a nearly flat appearance.
Previously, our Classic model featured a base of 6, whereas our new models utilize a base of 4.
![5.PNG](./5.PNG)
### Step 7: DESIGN THE MOULD
When designing molds for eyewear, it is important to balance costs with quality. Achieving excellent inscriptions and surface finishes requires significant investment. For testing, molds can be produced more quickly and economically with basic equipment. It is crucial to recognize that creating molds comparable to industrial ones is not cost-effective. A high-quality mold requiring minimal post-processing was chosen.
![6.PNG](./6.PNG)
### Step 8: Parting lines
If choosing a cheaper mold, place parting lines at the edges to simplify post-processing and achieve satisfactory results.
For high-quality molds, the placement of parting lines is less critical as minimal post-processing, such as slight polishing, may be needed. Design choices can guide your decision. The images illustrate how to obscure parting lines with a rounding technique, which increases mold cost—particularly for small features requiring multiple tool changes and additional time—or how to maintain a simple design.
![7.PNG](./7.PNG)
![8.PNG](./8.PNG)
### Step 9: Closing system: How complex?
### Closing System: Complexity Overview
A closing system enabling quicker production can be expensive. The clamping pressure in an injection mold is crucial for optimal results and mold longevity. Finding a system that is affordable, accommodates frequent mold changes, and provides adequate, evenly distributed pressure is challenging.
Simple screws are a budget-friendly solution, offering excellent clamping pressure when correctly positioned. However, they may slow down the process of opening and closing the mold. We suggest beginning with screws to assess your actual requirements before considering other options.
![9.PNG](./9.PNG)
![10.PNG](./10.PNG)
![11.PNG](./11.PNG)
### Step 10: Surface finishings
### Surface Finishing Options for Molds
1. **Tool Paths**: Leaving tool paths is cost-effective and allows for creative patterns by altering cutting directions.
2. **Bead Blasting**: Provides an even surface at a low cost but lacks a shiny finish. Standards vary regionally, so consult your manufacturing partner for guidance.
3. **Polishing**: Achieves the smoothest finish but is the most expensive. Choose the appropriate grade for your needs.
![12.PNG](./12.PNG)
### Step 11: Logos and inscriptions
To finish your product, consider adding inscriptions to ensure recipients know its origin. Two main methods are:
1. Milling a logo or inscription. This approach limits production to one brand, but allows for high-quality inscriptions with minimal effort or time. The image shows molds made for Experiencia Emprendedora in Argentina.
2. Using pressure-marking to imprint logos and inscriptions. While the quality is lower, this method allows the mold to be used for multiple projects and brands as you establish your brand, if desired.
![13.png](./13.png)
![14.PNG](./14.PNG)
### Step 12: GET READY TO INJECT THOUSANDS!
Once you comprehend the process, adjust it to suit your machines, molds, and products to achieve your objectives. Automation may be beneficial as sales become consistent. Pay close attention to color formulas for your products.
![15.PNG](./15.PNG)
### Step 13: EMBRACE DISTRIBUTED DESIGN
### Distributed Eyewear Production
At FOS, we enable local production of our eyewear designs, reducing the need for individual product shipments. We offer resources and moulds to facilitate this process, allowing the manufacture of eyewear products anywhere.
Distributed design is an impactful approach that we support through our offerings. For more details on our packages, please visit our website.
#### Contact
- Website: [fosbarcelona.com](https://www.fosbarcelona.com/)
- Instagram: [instagram.com](https://www.instagram.com/)
![FOS_sotllo_front15.jpg](./FOS_sotllo_front15.jpg)
![isometriques_sotllo3.jpg](./isometriques_sotllo3.jpg)
![16.PNG](./16.PNG)
## Resources
### Tools & Equipment
- CNC milling machine ([source](https://www.fosbarcelona.com/))
- Injection molding machine ([source](https://www.fosbarcelona.com/))
- Screw-based clamping system ([source](https://www.fosbarcelona.com/))
- Bead blasting equipment ([source](https://www.fosbarcelona.com/))
- Polishing tools ([source](https://www.fosbarcelona.com/))
### Software
- CAD software ([source](https://www.fosbarcelona.com/))
### Components & Materials
- Metal hinges (riveted, in-mold, screwed-in, fused) ([source](https://www.fosbarcelona.com/))
- Plastic hinges ([source](https://www.fosbarcelona.com/))
- Polycarbonate/CR-39/mineral lenses ([source](https://www.fosbarcelona.com/))
- Color pigments/formulas ([source](https://www.fosbarcelona.com/))
- Tool-path or bead-blasted molds ([source](https://www.fosbarcelona.com/))
### Additional Resources
- [FOS Barcelona Production Guide](https://www.fosbarcelona.com/)
- [Design & Manufacturing Support](https://www.instagram.com/)
## References
## References
### Articles
- <https://distributeddesign.eu/bridging-the-gap-between-3d-printing-and-small-scale-batch-production-with-open-source-plastic-recycling-machines/>
- <https://www.designboom.com/design/fos-handcraft-your-own-sunglasses-plastic-waste-03-11-2019/>
- <https://inhabitat.com/make-your-own-custom-sunglasses-from-recycled-plastic-with-fos/>
- <https://www.designboom.com/design/fos-project-recycled-plastic-lamps-07-01-2016/>
### Open-source Designs
- https://community.preciousplastic.com/library/design-moulds-for-sunglasses
### YouTube
- <https://www.youtube.com/watch?v=9Tyy6oZfFBg>

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---
title: Design moulds for sunglasses
slug: design-moulds-for-sunglasses
description: For the past five years, Esfèrica has focused on maintaining the value of waste plastics. Our project, FOS Barcelona, produces eyewear from local waste and provides molds for others to produce them locally, promoting distributed design.
This guide shares insights from our experience.
1: Requirements
2-5: Sunglasses Design
6-10: Mold Design
tags: ["mould","injection","product"]
category: uncategorized
difficulty: Hard
time: 3-4 weeks
location: Barcelona, Spain
---
import { Image } from 'astro:assets'
# Design moulds for sunglasses
<Image src={import('./_IGP9762.jpg')} alt="Design moulds for sunglasses" />
For the past five years, Esfèrica has focused on maintaining the value of waste plastics. Our project, FOS Barcelona, produces eyewear from local waste and provides molds for others to produce them locally, promoting distributed design.
This guide shares insights from our experience.
1: Requirements
2-5: Sunglasses Design
6-10: Mold Design
User Location: Barcelona, Spain
## Steps
### Step 1: What you need
To complete the process independently, you will need:
1. A defined model concept.
2. A computer with CAD software experience.
3. Access to a quality CNC milling machine or a manufacturing partner.
4. An injection machine.
Let's proceed with the steps.
<Image src={import('./00.jpg')} alt="00.jpg" />
### Step 2: DESIGN THE SUNGLASSES
When designing eyewear, you can either choose bold designs aimed at a niche audience or opt for classic styles for broader appeal. Your decision depends on your goals. Once your target is set, you will need to make decisions about various components, as outlined in the following steps.
<Image src={import('./1.png')} alt="1.png" />
### Step 3: Sunglasses model - Hinges
Metal hinges: Common options include riveted (fixed with rivets), in-mold (placed before injection), screwed-in (attached post-injection with screws), and fused (secured post-injection with heat). Screw-in hinges are the easiest to detach after the product's lifespan.
Plastic hinges: See next step.
<Image src={import('./22.PNG')} alt="22.PNG" />
### Step 4: Sunglasses model - Hinges
Plastic hinges can be manufactured using molds. This method avoids material mixtures and can offer durability comparable to metal hinges if designed correctly. However, the perceived quality might be a concern when creating products for sale, as perceptions can vary globally and are not always aligned with actual quality.
<Image src={import('./3.PNG')} alt="3.PNG" />
### Step 5: Sunglasses model - Lenses
There is a wide variety of lenses available. Your choice depends on the intended use and type of eyewear. The main types are:
- Polycarbonate: Suitable for sports and action eyewear due to durability.
- CR-39 (polymer): The most common type of lens.
- Mineral: Glass lenses, used less frequently due to weight and fragility, but offer high scratch resistance.
<Image src={import('./4.png')} alt="4.png" />
### Step 6: Sunglasses Model - Base
Certainly.
---
For eyewear design, the curvature of the frame is determined by the "Base" value. A higher base number results in a smaller curvature diameter. Base 9 is typical for sports eyewear, providing a snug fit to protect the eyes, while base 2 is used for fashion eyewear with a nearly flat appearance.
Previously, our Classic model featured a base of 6, whereas our new models utilize a base of 4.
<Image src={import('./5.PNG')} alt="5.PNG" />
### Step 7: DESIGN THE MOULD
When designing molds for eyewear, it is important to balance costs with quality. Achieving excellent inscriptions and surface finishes requires significant investment. For testing, molds can be produced more quickly and economically with basic equipment. It is crucial to recognize that creating molds comparable to industrial ones is not cost-effective. A high-quality mold requiring minimal post-processing was chosen.
<Image src={import('./6.PNG')} alt="6.PNG" />
### Step 8: Parting lines
If choosing a cheaper mold, place parting lines at the edges to simplify post-processing and achieve satisfactory results.
For high-quality molds, the placement of parting lines is less critical as minimal post-processing, such as slight polishing, may be needed. Design choices can guide your decision. The images illustrate how to obscure parting lines with a rounding technique, which increases mold cost—particularly for small features requiring multiple tool changes and additional time—or how to maintain a simple design.
<Image src={import('./7.PNG')} alt="7.PNG" />
<Image src={import('./8.PNG')} alt="8.PNG" />
### Step 9: Closing system: How complex?
### Closing System: Complexity Overview
A closing system enabling quicker production can be expensive. The clamping pressure in an injection mold is crucial for optimal results and mold longevity. Finding a system that is affordable, accommodates frequent mold changes, and provides adequate, evenly distributed pressure is challenging.
Simple screws are a budget-friendly solution, offering excellent clamping pressure when correctly positioned. However, they may slow down the process of opening and closing the mold. We suggest beginning with screws to assess your actual requirements before considering other options.
<Image src={import('./9.PNG')} alt="9.PNG" />
<Image src={import('./10.PNG')} alt="10.PNG" />
<Image src={import('./11.PNG')} alt="11.PNG" />
### Step 10: Surface finishings
### Surface Finishing Options for Molds
1. **Tool Paths**: Leaving tool paths is cost-effective and allows for creative patterns by altering cutting directions.
2. **Bead Blasting**: Provides an even surface at a low cost but lacks a shiny finish. Standards vary regionally, so consult your manufacturing partner for guidance.
3. **Polishing**: Achieves the smoothest finish but is the most expensive. Choose the appropriate grade for your needs.
<Image src={import('./12.PNG')} alt="12.PNG" />
### Step 11: Logos and inscriptions
To finish your product, consider adding inscriptions to ensure recipients know its origin. Two main methods are:
1. Milling a logo or inscription. This approach limits production to one brand, but allows for high-quality inscriptions with minimal effort or time. The image shows molds made for Experiencia Emprendedora in Argentina.
2. Using pressure-marking to imprint logos and inscriptions. While the quality is lower, this method allows the mold to be used for multiple projects and brands as you establish your brand, if desired.
<Image src={import('./13.png')} alt="13.png" />
<Image src={import('./14.PNG')} alt="14.PNG" />
### Step 12: GET READY TO INJECT THOUSANDS!
Once you comprehend the process, adjust it to suit your machines, molds, and products to achieve your objectives. Automation may be beneficial as sales become consistent. Pay close attention to color formulas for your products.
<Image src={import('./15.PNG')} alt="15.PNG" />
### Step 13: EMBRACE DISTRIBUTED DESIGN
### Distributed Eyewear Production
At FOS, we enable local production of our eyewear designs, reducing the need for individual product shipments. We offer resources and moulds to facilitate this process, allowing the manufacture of eyewear products anywhere.
Distributed design is an impactful approach that we support through our offerings. For more details on our packages, please visit our website.
#### Contact
- Website: [fosbarcelona.com](https://www.fosbarcelona.com/)
- Instagram: [instagram.com](https://www.instagram.com/)
<Image src={import('./FOS_sotllo_front15.jpg')} alt="FOS_sotllo_front15.jpg" />
<Image src={import('./isometriques_sotllo3.jpg')} alt="isometriques_sotllo3.jpg" />
<Image src={import('./16.PNG')} alt="16.PNG" />

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## References
### Articles
- <https://distributeddesign.eu/bridging-the-gap-between-3d-printing-and-small-scale-batch-production-with-open-source-plastic-recycling-machines/>
- <https://www.designboom.com/design/fos-handcraft-your-own-sunglasses-plastic-waste-03-11-2019/>
- <https://inhabitat.com/make-your-own-custom-sunglasses-from-recycled-plastic-with-fos/>
- <https://www.designboom.com/design/fos-project-recycled-plastic-lamps-07-01-2016/>
### Open-source Designs
- https://community.preciousplastic.com/library/design-moulds-for-sunglasses
### YouTube
- <https://www.youtube.com/watch?v=9Tyy6oZfFBg>

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### Tools & Equipment
- CNC milling machine ([source](https://www.fosbarcelona.com/))
- Injection molding machine ([source](https://www.fosbarcelona.com/))
- Screw-based clamping system ([source](https://www.fosbarcelona.com/))
- Bead blasting equipment ([source](https://www.fosbarcelona.com/))
- Polishing tools ([source](https://www.fosbarcelona.com/))
### Software
- CAD software ([source](https://www.fosbarcelona.com/))
### Components & Materials
- Metal hinges (riveted, in-mold, screwed-in, fused) ([source](https://www.fosbarcelona.com/))
- Plastic hinges ([source](https://www.fosbarcelona.com/))
- Polycarbonate/CR-39/mineral lenses ([source](https://www.fosbarcelona.com/))
- Color pigments/formulas ([source](https://www.fosbarcelona.com/))
- Tool-path or bead-blasted molds ([source](https://www.fosbarcelona.com/))
### Additional Resources
- [FOS Barcelona Production Guide](https://www.fosbarcelona.com/)
- [Design & Manufacturing Support](https://www.instagram.com/)

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---
title: Double Face ( 2 colours ) Plastic Sheet
slug: double-face--2-colours--plastic-sheet-
description: # Building a Double Face Sheet Press
## Required Materials and Tools
1. **Materials**
- Steel sheets
- Bolts and nuts
- Metal bars
2. **Tools**
- Welding machine
- Drill
- Measuring tape
## Assembly Instructions
1. **Frame Construction**
- Cut the metal bars to size (ensure all bars are equal in length: 1 meter or 39.37 inches).
- Weld the bars at right angles to form a rectangular frame.
2. **Sheet Attachment**
- Drill holes into each corner of the steel sheets (0.1 inches or 2.54 mm in diameter).
- Align sheets with the frame and secure with bolts and nuts.
3. **Final Adjustments**
- Ensure all connections are tight and secure.
- Test the press for stability before use.
This guide provides fundamental steps to construct your press efficiently.
tags: ["mould","sheetpress"]
category: uncategorized
difficulty: Easy
time: < 1 hour
keywords: double face sheet press, steel sheet assembly, DIY metal frame, welding and drilling, sheet attachment process, construction materials, mold preparation, temperature control, creating smooth surfaces, DIY double-sided projects
location: Rio de Janeiro, Brazil
---
# Double Face ( 2 colours ) Plastic Sheet
![Double Face ( 2 colours ) Plastic Sheet ](final_1-18a62002431.jpg)
# Building a Double Face Sheet Press
## Required Materials and Tools
1. **Materials**
- Steel sheets
- Bolts and nuts
- Metal bars
2. **Tools**
- Welding machine
- Drill
- Measuring tape
## Assembly Instructions
1. **Frame Construction**
- Cut the metal bars to size (ensure all bars are equal in length: 1 meter or 39.37 inches).
- Weld the bars at right angles to form a rectangular frame.
2. **Sheet Attachment**
- Drill holes into each corner of the steel sheets (0.1 inches or 2.54 mm in diameter).
- Align sheets with the frame and secure with bolts and nuts.
3. **Final Adjustments**
- Ensure all connections are tight and secure.
- Test the press for stability before use.
This guide provides fundamental steps to construct your press efficiently.
User Location: Rio de Janeiro, Brazil
## Steps
### Step 1: Material Preparation
Ensure that the mold is clean and silicon is applied to prevent plastic from sticking.
Begin by choosing two colors and weighing the material to match your mold's capacity. For instance, if your sheet requires 3 lbs (1400 g), weigh 1.5 lbs (700 g) each of orange and blue flakes.
![WhatsApp Image 2023-09-01 at 17.10.27-18a61f28a85.jpg](./WhatsApp_Image_2023-09-01_at_17.10.27-18a61f28a85.jpg)
![Prep 2-18a61f29fd7.jpg](./Prep_2-18a61f29fd7.jpg)
![Layer 1-18a61f41192.jpg](./Layer_1-18a61f41192.jpg)
### Step 2: Melt your plastic by layers
Place the single-colored flakes into the molds and melt them at a low temperature, approximately 320°F (160°C). Avoid high temperatures as the cover mold is not yet in use.
Once the first layer is evenly melted, add a second layer (such as blue) and apply the top mold. Act quickly to prevent the first layer from cooling too rapidly and forming a surface division.
Return the assembly to the oven until the new layer melts, which typically takes about 15 minutes at a slightly increased temperature of 356 - 374°F (180 - 190°C).
![layer 1.1-18a61f43546.jpg](./layer_1.1-18a61f43546.jpg)
![layer 1.2-18a61f44acb.jpg](./layer_1.2-18a61f44acb.jpg)
![layer 2-18a61f57d69.jpg](./layer_2-18a61f57d69.jpg)
### Step 3: Finalize your sheet
After removing from the oven, press the mold in the sheet press to eliminate bubbles and achieve a smooth surface.
Once pressed and cooled, your sheet is ready for use. Consider creating items like double-sided shelves, stools, or tables.
![layer 2.1-18a61fe0601.jpg](./layer_2.1-18a61fe0601.jpg)
![final 1-18a61fe2085.jpg](./final_1-18a61fe2085.jpg)
![final 2-18a61fe31d3.jpg](./final_2-18a61fe31d3.jpg)
## Resources
### Tools
- Welding machine
- Drill
- Measuring tape
and other essential tools are required for assembly. Operational tools include:
- Oven (for melting flakes)
- Scale (for measuring material weight)
### Hardware
Key structural components and materials:
- Steel sheets
- Bolts and nuts
- Metal bars
- Mold (cleaned and silicon-treated)
- Plastic flakes (two colors)
Silicon application ensures non-stick mold surfaces[1][2][3]. Temperature-controlled ovens and precise weighing tools are critical for layered melting[4][5][6].
## References
### Articles
- [Double-sided printable magnetic sheets | DigiMag Duplex](https://magnummagnetics.com/digimag-duplex/)
- [Best Practices for Press-Fit Assembly](https://www.assemblymag.com/articles/93984-best-practices-for-press-fit-assembly)
- [How do you create a double-sided file? - Adobe Community](https://community.adobe.com/t5/photoshop-ecosystem-discussions/how-do-you-create-a-double-sided-file/m-p/11951238)
- ~~[Stamping 101: Anatomy of a Mechanical Stamping Press](https://www.thefabricator.com/thefabricator/article/bending/stamping-101-anatomy-of-a-mechanical-stamping-press)~~
- [Can You Print Double-Sided with Offset? Tips for Accurate Results](https://www.vslprint.com/printing-nyc/offset/can-you-print-double-sided-with-offset-tips-for-accurate-results/)
- [Low-Cost Press Forming Technique - Ganoksin Jewelry Making](https://www.ganoksin.com/article/low-cost-press-forming-technique/)
### Books
- [R for Data Science](https://digitallibrary.tsu.ge/book/2019/september/books/R-for-Data-Science.pdf)
### Papers
- [Pressing - AstenJohnson](https://www.astenjohnson.com/img/chapter-previews/chapter-3.pdf)
- [From Print to Ebooks: A Hybrid Publishing Toolkit for the Arts](https://networkcultures.org/wp-content/uploads/2014/12/0419-HVA_DPT_from_print_to_ebooks_OS_RGB_aanp_lr_totaal.pdf)
- [EasyEDA Tutorial](https://image.easyeda.com/files/EasyEDA-Tutorial_v6.4.32.pdf)
### YouTube
- [Build a PRO sheetpress machine and make sheets (part 3.7)](https://www.youtube.com/watch?v=j3OctDe3xVk)
- [The Open Press Project - The Open Source #3DPrinted Printing Press](https://www.youtube.com/watch?v=uFCi9vd_tmo)
- [How To Make A Plastic Sheet With A Sheetpress?! | By Wedoo](https://www.youtube.com/watch?v=nQEvEjdvToQ)
### Open-source Designs
- [DIY Sheet Press - Dave Hakkens](https://davehakkens.nl/community/forums/topic/diy-sheet-press/index.html)
- 1.5x1.5 Meter Sheet Press machine
- Start a Sheetpress Workspace to Recycle Plastic
- SHEET PRESS MACHINE 1x1 Meter ( CE Certified & Factory Made)

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"text": "Place all the one coloured flakes into the moulds and melt it at low temperature ( around 160 C using our oven). The temperature should not be so high since we are not yet using the cover mould on top. \n\nOnce the first layer is homogeneously melted, put the other layer ( in our case, blue) on top of the melted layers and cover it with the top mould. Attention: try to be quick in this procedure to avoid that the first layer cools off too fast and create a surface division. \n\nPut it back into the oven until the new layer is also melted ( around 15min in our oven). Here we raised a bit the temperature to 180 - 190 C. ",
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"text": "After the oven, make sure you press the mould in the sheet press to remove all bubbles and ensure a smooth surface! \n\nAfter pressing and cooling, your sheet is ready! Explore the several creative things you can do with such sheets such as double-face shelves, stools, tables and so on! ;) ",
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"content": "# Building a Double Face Sheet Press\n\n## Required Materials and Tools\n\n1. **Materials**\n - Steel sheets\n - Bolts and nuts\n - Metal bars\n\n2. **Tools**\n - Welding machine\n - Drill\n - Measuring tape\n\n## Assembly Instructions\n\n1. **Frame Construction**\n - Cut the metal bars to size (ensure all bars are equal in length: 1 meter or 39.37 inches).\n - Weld the bars at right angles to form a rectangular frame.\n\n2. **Sheet Attachment**\n - Drill holes into each corner of the steel sheets (0.1 inches or 2.54 mm in diameter).\n - Align sheets with the frame and secure with bolts and nuts.\n\n3. **Final Adjustments**\n - Ensure all connections are tight and secure.\n - Test the press for stability before use. \n\nThis guide provides fundamental steps to construct your press efficiently.\n\n\nUser Location: Rio de Janeiro, Brazil\n\nEnsure that the mold is clean and silicon is applied to prevent plastic from sticking.\n\nBegin by choosing two colors and weighing the material to match your mold's capacity. For instance, if your sheet requires 3 lbs (1400 g), weigh 1.5 lbs (700 g) each of orange and blue flakes.\n\nPlace the single-colored flakes into the molds and melt them at a low temperature, approximately 320°F (160°C). Avoid high temperatures as the cover mold is not yet in use.\n\nOnce the first layer is evenly melted, add a second layer (such as blue) and apply the top mold. Act quickly to prevent the first layer from cooling too rapidly and forming a surface division.\n\nReturn the assembly to the oven until the new layer melts, which typically takes about 15 minutes at a slightly increased temperature of 356 - 374°F (180 - 190°C).\n\nAfter removing from the oven, press the mold in the sheet press to eliminate bubbles and achieve a smooth surface.\n\nOnce pressed and cooled, your sheet is ready for use. Consider creating items like double-sided shelves, stools, or tables.",
"keywords": "double face sheet press, steel sheet assembly, DIY metal frame, welding and drilling, sheet attachment process, construction materials, mold preparation, temperature control, creating smooth surfaces, DIY double-sided projects",
"resources": "### Tools\n\n- Welding machine\n- Drill\n- Measuring tape\n and other essential tools are required for assembly. Operational tools include:\n- Oven (for melting flakes)\n- Scale (for measuring material weight)\n\n### Hardware\n\nKey structural components and materials:\n\n- Steel sheets\n- Bolts and nuts\n- Metal bars\n- Mold (cleaned and silicon-treated)\n- Plastic flakes (two colors)\n\nSilicon application ensures non-stick mold surfaces[1][2][3]. Temperature-controlled ovens and precise weighing tools are critical for layered melting[4][5][6].",
"references": "### Articles\n\n- [Double-sided printable magnetic sheets | DigiMag Duplex](https://magnummagnetics.com/digimag-duplex/)\n- [Best Practices for Press-Fit Assembly](https://www.assemblymag.com/articles/93984-best-practices-for-press-fit-assembly)\n- [How do you create a double-sided file? - Adobe Community](https://community.adobe.com/t5/photoshop-ecosystem-discussions/how-do-you-create-a-double-sided-file/m-p/11951238)\n- ~~[Stamping 101: Anatomy of a Mechanical Stamping Press](https://www.thefabricator.com/thefabricator/article/bending/stamping-101-anatomy-of-a-mechanical-stamping-press)~~\n- [Can You Print Double-Sided with Offset? Tips for Accurate Results](https://www.vslprint.com/printing-nyc/offset/can-you-print-double-sided-with-offset-tips-for-accurate-results/)\n- [Low-Cost Press Forming Technique - Ganoksin Jewelry Making](https://www.ganoksin.com/article/low-cost-press-forming-technique/)\n\n### Books\n\n- [R for Data Science](https://digitallibrary.tsu.ge/book/2019/september/books/R-for-Data-Science.pdf)\n\n### Papers\n\n- [Pressing - AstenJohnson](https://www.astenjohnson.com/img/chapter-previews/chapter-3.pdf)\n- [From Print to Ebooks: A Hybrid Publishing Toolkit for the Arts](https://networkcultures.org/wp-content/uploads/2014/12/0419-HVA_DPT_from_print_to_ebooks_OS_RGB_aanp_lr_totaal.pdf)\n- [EasyEDA Tutorial](https://image.easyeda.com/files/EasyEDA-Tutorial_v6.4.32.pdf)\n\n### YouTube\n\n- [Build a PRO sheetpress machine and make sheets (part 3.7)](https://www.youtube.com/watch?v=j3OctDe3xVk)\n- [The Open Press Project - The Open Source #3DPrinted Printing Press](https://www.youtube.com/watch?v=uFCi9vd_tmo)\n- [How To Make A Plastic Sheet With A Sheetpress?! | By Wedoo](https://www.youtube.com/watch?v=nQEvEjdvToQ)\n\n### Open-source Designs\n\n- [DIY Sheet Press - Dave Hakkens](https://davehakkens.nl/community/forums/topic/diy-sheet-press/index.html)\n- 1.5x1.5 Meter Sheet Press machine\n- Start a Sheetpress Workspace to Recycle Plastic\n- SHEET PRESS MACHINE 1x1 Meter ( CE Certified & Factory Made)"
}

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View File

@ -0,0 +1,119 @@
---
title: Double Face ( 2 colours ) Plastic Sheet
slug: double-face--2-colours--plastic-sheet-
description: # Building a Double Face Sheet Press
## Required Materials and Tools
1. **Materials**
- Steel sheets
- Bolts and nuts
- Metal bars
2. **Tools**
- Welding machine
- Drill
- Measuring tape
## Assembly Instructions
1. **Frame Construction**
- Cut the metal bars to size (ensure all bars are equal in length: 1 meter or 39.37 inches).
- Weld the bars at right angles to form a rectangular frame.
2. **Sheet Attachment**
- Drill holes into each corner of the steel sheets (0.1 inches or 2.54 mm in diameter).
- Align sheets with the frame and secure with bolts and nuts.
3. **Final Adjustments**
- Ensure all connections are tight and secure.
- Test the press for stability before use.
This guide provides fundamental steps to construct your press efficiently.
tags: ["mould","sheetpress"]
category: uncategorized
difficulty: Easy
time: < 1 hour
location: Rio de Janeiro, Brazil
---
import { Image } from 'astro:assets'
# Double Face ( 2 colours ) Plastic Sheet
<Image src={import('./final_1-18a62002431.jpg')} alt="Double Face ( 2 colours ) Plastic Sheet " />
# Building a Double Face Sheet Press
## Required Materials and Tools
1. **Materials**
- Steel sheets
- Bolts and nuts
- Metal bars
2. **Tools**
- Welding machine
- Drill
- Measuring tape
## Assembly Instructions
1. **Frame Construction**
- Cut the metal bars to size (ensure all bars are equal in length: 1 meter or 39.37 inches).
- Weld the bars at right angles to form a rectangular frame.
2. **Sheet Attachment**
- Drill holes into each corner of the steel sheets (0.1 inches or 2.54 mm in diameter).
- Align sheets with the frame and secure with bolts and nuts.
3. **Final Adjustments**
- Ensure all connections are tight and secure.
- Test the press for stability before use.
This guide provides fundamental steps to construct your press efficiently.
User Location: Rio de Janeiro, Brazil
## Steps
### Step 1: Material Preparation
Ensure that the mold is clean and silicon is applied to prevent plastic from sticking.
Begin by choosing two colors and weighing the material to match your mold's capacity. For instance, if your sheet requires 3 lbs (1400 g), weigh 1.5 lbs (700 g) each of orange and blue flakes.
<Image src={import('./WhatsApp_Image_2023-09-01_at_17.10.27-18a61f28a85.jpg')} alt="WhatsApp Image 2023-09-01 at 17.10.27-18a61f28a85.jpg" />
<Image src={import('./Prep_2-18a61f29fd7.jpg')} alt="Prep 2-18a61f29fd7.jpg" />
<Image src={import('./Layer_1-18a61f41192.jpg')} alt="Layer 1-18a61f41192.jpg" />
### Step 2: Melt your plastic by layers
Place the single-colored flakes into the molds and melt them at a low temperature, approximately 320°F (160°C). Avoid high temperatures as the cover mold is not yet in use.
Once the first layer is evenly melted, add a second layer (such as blue) and apply the top mold. Act quickly to prevent the first layer from cooling too rapidly and forming a surface division.
Return the assembly to the oven until the new layer melts, which typically takes about 15 minutes at a slightly increased temperature of 356 - 374°F (180 - 190°C).
<Image src={import('./layer_1.1-18a61f43546.jpg')} alt="layer 1.1-18a61f43546.jpg" />
<Image src={import('./layer_1.2-18a61f44acb.jpg')} alt="layer 1.2-18a61f44acb.jpg" />
<Image src={import('./layer_2-18a61f57d69.jpg')} alt="layer 2-18a61f57d69.jpg" />
### Step 3: Finalize your sheet
After removing from the oven, press the mold in the sheet press to eliminate bubbles and achieve a smooth surface.
Once pressed and cooled, your sheet is ready for use. Consider creating items like double-sided shelves, stools, or tables.
<Image src={import('./layer_2.1-18a61fe0601.jpg')} alt="layer 2.1-18a61fe0601.jpg" />
<Image src={import('./final_1-18a61fe2085.jpg')} alt="final 1-18a61fe2085.jpg" />
<Image src={import('./final_2-18a61fe31d3.jpg')} alt="final 2-18a61fe31d3.jpg" />

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### Articles
- [Double-sided printable magnetic sheets | DigiMag Duplex](https://magnummagnetics.com/digimag-duplex/)
- [Best Practices for Press-Fit Assembly](https://www.assemblymag.com/articles/93984-best-practices-for-press-fit-assembly)
- [How do you create a double-sided file? - Adobe Community](https://community.adobe.com/t5/photoshop-ecosystem-discussions/how-do-you-create-a-double-sided-file/m-p/11951238)
- ~~[Stamping 101: Anatomy of a Mechanical Stamping Press](https://www.thefabricator.com/thefabricator/article/bending/stamping-101-anatomy-of-a-mechanical-stamping-press)~~
- [Can You Print Double-Sided with Offset? Tips for Accurate Results](https://www.vslprint.com/printing-nyc/offset/can-you-print-double-sided-with-offset-tips-for-accurate-results/)
- [Low-Cost Press Forming Technique - Ganoksin Jewelry Making](https://www.ganoksin.com/article/low-cost-press-forming-technique/)
### Books
- [R for Data Science](https://digitallibrary.tsu.ge/book/2019/september/books/R-for-Data-Science.pdf)
### Papers
- [Pressing - AstenJohnson](https://www.astenjohnson.com/img/chapter-previews/chapter-3.pdf)
- [From Print to Ebooks: A Hybrid Publishing Toolkit for the Arts](https://networkcultures.org/wp-content/uploads/2014/12/0419-HVA_DPT_from_print_to_ebooks_OS_RGB_aanp_lr_totaal.pdf)
- [EasyEDA Tutorial](https://image.easyeda.com/files/EasyEDA-Tutorial_v6.4.32.pdf)
### YouTube
- [Build a PRO sheetpress machine and make sheets (part 3.7)](https://www.youtube.com/watch?v=j3OctDe3xVk)
- [The Open Press Project - The Open Source #3DPrinted Printing Press](https://www.youtube.com/watch?v=uFCi9vd_tmo)
- [How To Make A Plastic Sheet With A Sheetpress?! | By Wedoo](https://www.youtube.com/watch?v=nQEvEjdvToQ)
### Open-source Designs
- [DIY Sheet Press - Dave Hakkens](https://davehakkens.nl/community/forums/topic/diy-sheet-press/index.html)
- 1.5x1.5 Meter Sheet Press machine
- Start a Sheetpress Workspace to Recycle Plastic
- SHEET PRESS MACHINE 1x1 Meter ( CE Certified & Factory Made)

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### Tools
- Welding machine
- Drill
- Measuring tape
and other essential tools are required for assembly. Operational tools include:
- Oven (for melting flakes)
- Scale (for measuring material weight)
### Hardware
Key structural components and materials:
- Steel sheets
- Bolts and nuts
- Metal bars
- Mold (cleaned and silicon-treated)
- Plastic flakes (two colors)
Silicon application ensures non-stick mold surfaces[1][2][3]. Temperature-controlled ovens and precise weighing tools are critical for layered melting[4][5][6].

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---
title: Extrude a Bird Feeder
slug: extrude-a-bird-feeder
description: Bird Feeder Made from Recycled Plastic using an Extruder
For detailed instructions, visit our blog and view the video:
[Link to Blog](https://menorplastic.com/disenamos-el-mejor-comedero-para-pajaros-con-plastico-reciclado/)
tags: ["PP","HDPE","extrusion","product"]
category: Products
difficulty: Easy
time: < 1 week
keywords: bird feeder, recycled plastic bird feeder, extruder bird feeder, eco-friendly bird feeder, how to make bird feeder, DIY bird feeder, HDPE bird feeder, sustainable bird feeder, bird feeder tutorial, bird feeder Spain
location: San Javier, Spain
---
# Extrude a Bird Feeder
![Extrude a Bird Feeder](WhatsApp_Image_2020-04-04_at_16.50.08_1.jpeg)
Bird Feeder Made from Recycled Plastic using an Extruder
For detailed instructions, visit our blog and view the video:
[Link to Blog](https://menorplastic.com/disenamos-el-mejor-comedero-para-pajaros-con-plastico-reciclado/)
User Location: San Javier, Spain
## Steps
### Step 1: Select plastics
Crush the plastic intended for use (preferably HDPE) and fill the extruder.
![WhatsApp Image 2020-04-04 at 16.50.09 (4).jpeg](./WhatsApp_Image_2020-04-04_at_16.50.09_4.jpeg)
![WhatsApp Image 2020-04-04 at 16.50.09 (3).jpeg](./WhatsApp_Image_2020-04-04_at_16.50.09_3.jpeg)
### Step 2: Pick some cardboard
Use cardboard tubes from toilet paper rolls or similar items. Place some fabric inside.
![WhatsApp Image 2020-04-04 at 16.50.09 (2).jpeg](./WhatsApp_Image_2020-04-04_at_16.50.09_2.jpeg)
### Step 3: Rolling plastic
Gradually wrap the plastic around the cardboard, altering the direction for added strength.
![enrollando.png](./enrollando.png)
### Step 4: Demolding
We let it cool and then slowly remove the cardboard.
![enfriando.png](./enfriando.png)
![estructura.png](./estructura.png)
### Step 5: Feed it
Your bird feeder is now complete and ready for use.
![final-individual.png](./final-individual.png)
![WhatsApp Image 2020-04-04 at 16.50.08.jpeg](./WhatsApp_Image_2020-04-04_at_16.50.08.jpeg)
![20200403_115558A.jpg](./20200403_115558A.jpg)
## Resources
The tutorial outlines a process for creating a bird feeder from recycled HDPE plastic using basic fabrication techniques. Below is a breakdown of the required components:
### Hardware
- **Plastic extruder** (~~[Blog link](https://menorplastic.com/disenamos-el-mejor-comedero-para-pajaros-con-plastico-reciclado/)~~)
- **HDPE plastic crusher/shredder** (for recycling plastic)
- **Cardboard tubes** (e.g., toilet paper rolls)
- **Fabric strips** (to line the tubes during molding)
- **Cooling area** (ambient air for solidification)
### Tools
- No specialized tools mentioned beyond the extruder and crusher.
### Software
- Not required for this project.
The process emphasizes repurposing household items like cardboard tubes and fabric, paired with recycling equipment.
## References
### Articles
- ~~[Recycled Plastic Hopper Feeder](https://www.wildaboutbirds.com/recycled-plastic-hopper-feeder)~~
- [Sustainable Bird Feeders Offer Solutions](https://birdschoice.com/blogs/news/sustainable-bird-feeders-offer-solutions-to-attracting-birds-and-minimizing-plastic-waste)
### Tutorials/Guides
- [DIY Plastic Bottle Bird Feeder](https://www.instructables.com/DIY-Plastic-Bottle-Bird-Feeder/)
- [Acrylic Bird Feeder Guide](https://plasticsheetsshop.co.uk/diy/how-to-build-a-bird-feeder/)
- [Low Cost Plastic Extruder for Filament Production](https://www.instructables.com/Low-Cost-Plastic-Extruder-for-Fillament-Production/)
### Papers
- [RepRapable Recyclebot: Open source 3-D printable extruder](https://digitalcommons.mtu.edu/materials_fp/177/)
### YouTube
- [How to make an upcycled bird feeder from a plastic bottle | WWT](https://www.youtube.com/watch?v=Ben9e5p5y8s)
### Open-source Designs
- [RepRapable Recyclebot: Open source 3-D printable extruder](https://reprap.org/wiki/RepRapable_Recyclebot:_Open_source_3-D_printable_extruder_for_converting_plastic_to_3-D_printing_filament)

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"content": "Bird Feeder Made from Recycled Plastic using an Extruder\n\nFor detailed instructions, visit our blog and view the video: \n[Link to Blog](https://menorplastic.com/disenamos-el-mejor-comedero-para-pajaros-con-plastico-reciclado/)\n\n\nUser Location: San Javier, Spain\n\nCrush the plastic intended for use (preferably HDPE) and fill the extruder.\n\nUse cardboard tubes from toilet paper rolls or similar items. Place some fabric inside.\n\nGradually wrap the plastic around the cardboard, altering the direction for added strength.\n\nWe let it cool and then slowly remove the cardboard.\n\nYour bird feeder is now complete and ready for use.",
"keywords": "bird feeder, recycled plastic bird feeder, extruder bird feeder, eco-friendly bird feeder, how to make bird feeder, DIY bird feeder, HDPE bird feeder, sustainable bird feeder, bird feeder tutorial, bird feeder Spain",
"resources": "The tutorial outlines a process for creating a bird feeder from recycled HDPE plastic using basic fabrication techniques. Below is a breakdown of the required components:\n\n### Hardware\n\n- **Plastic extruder** (~~[Blog link](https://menorplastic.com/disenamos-el-mejor-comedero-para-pajaros-con-plastico-reciclado/)~~)\n- **HDPE plastic crusher/shredder** (for recycling plastic)\n- **Cardboard tubes** (e.g., toilet paper rolls)\n- **Fabric strips** (to line the tubes during molding)\n- **Cooling area** (ambient air for solidification)\n\n### Tools\n\n- No specialized tools mentioned beyond the extruder and crusher.\n\n### Software\n\n- Not required for this project.\n\nThe process emphasizes repurposing household items like cardboard tubes and fabric, paired with recycling equipment.",
"references": "### Articles\n\n- ~~[Recycled Plastic Hopper Feeder](https://www.wildaboutbirds.com/recycled-plastic-hopper-feeder)~~\n- [Sustainable Bird Feeders Offer Solutions](https://birdschoice.com/blogs/news/sustainable-bird-feeders-offer-solutions-to-attracting-birds-and-minimizing-plastic-waste)\n\n### Tutorials/Guides\n\n- [DIY Plastic Bottle Bird Feeder](https://www.instructables.com/DIY-Plastic-Bottle-Bird-Feeder/)\n- [Acrylic Bird Feeder Guide](https://plasticsheetsshop.co.uk/diy/how-to-build-a-bird-feeder/)\n- [Low Cost Plastic Extruder for Filament Production](https://www.instructables.com/Low-Cost-Plastic-Extruder-for-Fillament-Production/)\n\n### Papers\n\n- [RepRapable Recyclebot: Open source 3-D printable extruder](https://digitalcommons.mtu.edu/materials_fp/177/)\n\n### YouTube\n\n- [How to make an upcycled bird feeder from a plastic bottle | WWT](https://www.youtube.com/watch?v=Ben9e5p5y8s)\n\n### Open-source Designs\n\n- [RepRapable Recyclebot: Open source 3-D printable extruder](https://reprap.org/wiki/RepRapable_Recyclebot:_Open_source_3-D_printable_extruder_for_converting_plastic_to_3-D_printing_filament)"
}

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