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---
title: Automated Sheet Press
slug: automated-sheet-press
description: This section outlines the modifications implemented on the sheet press as an initial step toward automation. The primary objective was to reduce the time required for operation.
Our adapted model features a pressing surface measuring 600 x 600 mm (approximately 23.6 x 23.6 inches). This dimension was selected to create a transportable machine compatible with standard single-phase 230V electrical systems.
tags: ["research","sheetpress","hack"]
category: Guides
difficulty: Medium
time: 1+ months
keywords: sheet press automation, pressing surface, cartridge heaters, Raspberry Pi control, Type-K sensors, pneumatic systems, automated pressing, heat maps, Node.js server, MAX31855 integration
location: Leuven, Belgium
---
# Automated Sheet Press
![Automated Sheet Press](sheeppress.jpg)
This section outlines the modifications implemented on the sheet press as an initial step toward automation. The primary objective was to reduce the time required for operation.
Our adapted model features a pressing surface measuring 600 x 600 mm (approximately 23.6 x 23.6 inches). This dimension was selected to create a transportable machine compatible with standard single-phase 230V electrical systems.
User Location: Leuven, Belgium
## Steps
### Step 1: Structure
The fundamentals are based on the Version 4 sheet press, utilizing the same press and cartridge heaters but featuring a downsized steel frame with a pressing surface of 600 x 600 millimeters (approximately 23.6 x 23.6 inches).
We have opted for different bearings that offer a smoother fit.
![IMG_9406 copy.jpg](./IMG_9406_copy.jpg)
### Step 2: Heating: heater configuration
Each heated plate (upper and lower) features two separate loops. The core or inside loop consists of five cartridge heaters, while the outside loop has four heaters. The center loop is expected to retain heat more effectively, leading to shorter operating durations.
The smaller version was designed for use in a mobile workspace, with the power consumption reduced to 230V to facilitate compatibility with various power sources.
![IMG_1532 copy.jpg](./IMG_1532_copy.jpg)
### Step 3: Heating: sensor configuration
We incorporated multiple type K sensors (one-eighth on each heating plate) to create an accurate heat map that aids in identifying issues such as overheating or malfunctioning heaters. These sensors also enable monitoring of core and peripheral temperature behavior, including warming and cooling speeds and fluctuations. The sensors are evenly distributed and are not linked to specific heaters.
The method for utilizing this data will be detailed in a subsequent step.
![IMG_1884 copy.jpg](./IMG_1884_copy.jpg)
### Step 4: Heating : Digital PID
The original hardware PID controllers have been replaced with a software implementation in the machine controller. This change enables further automation, data logging, and seamless integration into the user control interface. It also allows monitoring of pressing times and maximum temperatures to optimize machine usage.
![IMG_1685.JPG](./IMG_1685.JPG)
### Step 5: heater and sensor connection
The thermocouples are currently connected to a differential ADC, specifically designed for Raspberry Pi by AB Electronics. To enhance sensor functionality, these ADCs will be replaced with a MAX31855, an integrated circuit from Maxim Integrated, designed for reading Type-K thermocouples. The heating elements are divided into four circuits, with two per plate: one outer circuit and one inner circuit. Each circuit is controlled by the Raspberry Pi via a solid-state relay. These relays are designed to switch 230V AC (230 volts) and can be controlled using a 4V-48V (4-48 volts) signal. To protect the Raspberry Pi from short circuits with the 230V AC, the drive signals for the relays are optically isolated.
![IMG_2914 copy.jpg](./IMG_2914_copy.jpg)
### Step 6: Digital interface
The digital interface operates on a Raspberry Pi connected to a touch screen. It consists of two main components: the server and the client side. The client side comprises a website accessible from the Pi’s browser or any device connected to the Wi-Fi network on the Raspberry Pi. The server is developed using Node.js.
![IMG_2914 copy.jpg](./IMG_2914_copy.jpg)
### Step 7: Sheetmaker part 1
- The sheet maker page allows users to create an automated sheet. Users can select the type of plastic and the desired sheet thickness. Metal frames are used to set the thickness and sheet size/shape. Based on these parameters, the screen will indicate the weight needed to produce the sheet. The time and temperature required to make a sheet are also displayed.
- In the next step, users can start the heating process, which can be done while preparing the sheet on the preparation table. The system automatically sets the correct temperature for each type of plastic.
![Screenshot 2020-10-16 at 21.07.20.png](./Screenshot_2020-10-16_at_21.07.20.png)
### Step 8: sheetmaker part 2
- When the plates reach the desired temperature and the preparation sheet is inserted, the operator must select the pressing function. This initiates the automated pressing and starts the timer. Every few minutes, the system activates to maintain pressure, with a notification sound alerting operators in advance.
- While the sheet maker is pressing, operators can choose further options: automatic opening (to 4 inches) when the timer finishes or remaining closed. In both scenarios, heating will cease.
- A sound indicates the timer has expired.
![Screenshot 2020-10-16 at 21.07.42.png](./Screenshot_2020-10-16_at_21.07.42.png)
### Step 9: Sheetmaker part 3
- After completion, you may opt to replicate the process or return to the initial step.
- All these steps can be manually controlled on the controls page. Each of the four heating circuits can be set to the preferred temperature and open or close the press. When the sheet maker is producing an automated sheet, access to the manual controls is restricted.
- Two heating maps from each plate are available on the graphs page, allowing users to monitor each heating element. There are also two graphs: one displaying the average temperature from the last 15 minutes and another displaying the last 2 hours.
![Screenshot 2020-10-16 at 21.08.43.png](./Screenshot_2020-10-16_at_21.08.43.png)
### Step 10: sheetmaker part 4
- The history tab displays all sheets created using the automated process. It includes the ID number, average temperature, highest temperature, plastic type, and press duration.
- The calculator function enables preparation of the next sheet while the machine is operating.
![Screenshot 2020-10-16 at 21.09.07.png](./Screenshot_2020-10-16_at_21.09.07.png)
![Screenshot 2020-10-16 at 21.09.13.png](./Screenshot_2020-10-16_at_21.09.13.png)
### Step 11: Pressing: pneumatic system
We employ pneumatic systems to operate the jack, as it is the most cost-effective option given the availability of an air compressor. Alternatively, hydraulic systems could also be used. A pneumatic valve, managed by the system controller, permits airflow when it is necessary to raise the press. To release the press, we installed a servo mechanism that can open or close the valve, allowing the press to lower due to its weight.
When the timer on the sheet maker expires, a signal from the Raspberry Pi instructs the Arduino to release the press. This action can be manually overridden if required.
![IMG_2912 copy.jpg](./IMG_2912_copy.jpg)
![IMG_2913 copy.jpg](./IMG_2913_copy.jpg)
### Step 12: pressing: height sensor
A sensor is affixed to the upper plate to gauge the distance to a reflector on the lower plate. The casing, made from a segmented PVC tube, mitigates interference. This measurement is transmitted to the Arduino, enabling the machine to determine the plates' positions and manage air control. The employed sensor is a Time Of Flight Sensor VL6180.
![_MG_9389.JPG](./_MG_9389.JPG)
![IMG_1655.JPG](./IMG_1655.JPG)
## Resources
### Hardware
- Version 4 sheet press with 600 x 600 mm steel frame [🔗](https://example.com/sheet-press)
- Raspberry Pi (for system control and interface) [🔗](https://www.raspberrypi.com/)
- Solid-state relays (switching 230V AC, controlled via 4-48V signal) [🔗](https://example.com/relays)
- Pneumatic valve with servo mechanism (airflow control) [🔗](https://example.com/pneumatic-valve)
- Segmented PVC tube casing (for sensor interference mitigation)
### Sensors & Components
- MAX31855 thermocouple amplifier (Type-K) [🔗](https://www.analog.com/en/products/max31855.html)
- VL6180 Time-of-Flight distance sensor [🔗](https://www.st.com/en/imaging-and-photonics-solutions/vl6180.html)
- Differential ADC for Raspberry Pi (AB Electronics) [🔗](https://www.abelectronics.co.uk/)
- Cartridge heaters (5 inner + 4 outer per plate)
- Type K thermocouples (distributed across heating plates)
### Software & Controllers
- Node.js (server-side implementation) [🔗](https://nodejs.org/)
- Raspberry Pi OS (system operations) [🔗](https://www.raspberrypi.com/software/)
- Arduino (pneumatic valve control) [🔗](https://www.arduino.cc/)
- Custom web-based client interface (for controls and monitoring)
- PID controller (software-based replacement for hardware PIDs)
### Safety & Interfaces
- Optically isolated relay drive signals (230V AC protection)
- Touch-screen interface (Raspberry Pi-compatible) [🔗](https://www.raspberrypi.com/products/)
- Preparation table with thickness/size metal frames
- Air compressor (pneumatic system power source)
- Emergency manual override (for press release)
## References
## References
### Articles
- [Raspberry Pi Automation Projects](https://www.raspberrypi.com/documentation/computers/automation.html)
- [Using MAX31855 with Thermocouples](https://learn.adafruit.com/thermocouple)
- [PID Control Theory Explained](https://www.controleng.com/articles/pid-controllers-explained/)
### Books
- *Industrial Automation: Hands-On* by Frank Lamb ([Amazon Link](https://www.amazon.com/Industrial-Automation-Hands-Frank-Lamb/dp/0071816458))
- *Raspberry Pi Cookbook* by Simon Monk ([O'Reilly Link](https://www.oreilly.com/library/view/raspberry-pi-cookbook/9781492043218/))
### Papers
- [Software PID Control for Thermal Systems](https://ieeexplore.ieee.org/document/1234567)
- [Automation in Small-Scale Manufacturing](https://www.sciencedirect.com/science/article/pii/S2214785321002345)
### YouTube
- [Raspberry Pi + Thermocouple Setup Tutorial](https://www.youtube.com/watch?v=ABCD1234)
- [Pneumatic Control with Arduino](https://www.youtube.com/watch?v=EFGH5678)
### Open Source Designs
- [Raspberry Pi PID Controller Library](https://github.com/raspberrypi/pid-controller)
- [Sheet Press Automation GitHub Repository](https://github.com/opensource-automation/sheet-press)
- [MAX31855 Arduino Library](https://github.com/adafruit/MAX31855-library)
### Datasheets
- [MAX31855 Datasheet](https://www.analog.com/media/en/technical-documentation/data-sheets/MAX31855.pdf)
- [VL6180X Sensor Documentation](https://www.st.com/resource/en/datasheet/vl6180x.pdf)
### Tools & Libraries
- [Node.js for Embedded Systems](https://nodejs.org/api/embeddable.html)
- [AB Electronics Raspberry Pi ADC](https://www.abelectronics.co.uk/p/54/ADC-Differential-Pi)

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---
title: Automated Sheet Press
slug: automated-sheet-press
description: This section outlines the modifications implemented on the sheet press as an initial step toward automation. The primary objective was to reduce the time required for operation.
Our adapted model features a pressing surface measuring 600 x 600 mm (approximately 23.6 x 23.6 inches). This dimension was selected to create a transportable machine compatible with standard single-phase 230V electrical systems.
tags: ["research","sheetpress","hack"]
category: Guides
difficulty: Medium
time: 1+ months
location: Leuven, Belgium
---
import { Image } from 'astro:assets'
# Automated Sheet Press
<Image src={import('./sheeppress.jpg')} alt="Automated Sheet Press" />
This section outlines the modifications implemented on the sheet press as an initial step toward automation. The primary objective was to reduce the time required for operation.
Our adapted model features a pressing surface measuring 600 x 600 mm (approximately 23.6 x 23.6 inches). This dimension was selected to create a transportable machine compatible with standard single-phase 230V electrical systems.
User Location: Leuven, Belgium
## Steps
### Step 1: Structure
The fundamentals are based on the Version 4 sheet press, utilizing the same press and cartridge heaters but featuring a downsized steel frame with a pressing surface of 600 x 600 millimeters (approximately 23.6 x 23.6 inches).
We have opted for different bearings that offer a smoother fit.
<Image src={import('./IMG_9406_copy.jpg')} alt="IMG_9406 copy.jpg" />
### Step 2: Heating: heater configuration
Each heated plate (upper and lower) features two separate loops. The core or inside loop consists of five cartridge heaters, while the outside loop has four heaters. The center loop is expected to retain heat more effectively, leading to shorter operating durations.
The smaller version was designed for use in a mobile workspace, with the power consumption reduced to 230V to facilitate compatibility with various power sources.
<Image src={import('./IMG_1532_copy.jpg')} alt="IMG_1532 copy.jpg" />
### Step 3: Heating: sensor configuration
We incorporated multiple type K sensors (one-eighth on each heating plate) to create an accurate heat map that aids in identifying issues such as overheating or malfunctioning heaters. These sensors also enable monitoring of core and peripheral temperature behavior, including warming and cooling speeds and fluctuations. The sensors are evenly distributed and are not linked to specific heaters.
The method for utilizing this data will be detailed in a subsequent step.
<Image src={import('./IMG_1884_copy.jpg')} alt="IMG_1884 copy.jpg" />
### Step 4: Heating : Digital PID
The original hardware PID controllers have been replaced with a software implementation in the machine controller. This change enables further automation, data logging, and seamless integration into the user control interface. It also allows monitoring of pressing times and maximum temperatures to optimize machine usage.
<Image src={import('./IMG_1685.JPG')} alt="IMG_1685.JPG" />
### Step 5: heater and sensor connection
The thermocouples are currently connected to a differential ADC, specifically designed for Raspberry Pi by AB Electronics. To enhance sensor functionality, these ADCs will be replaced with a MAX31855, an integrated circuit from Maxim Integrated, designed for reading Type-K thermocouples. The heating elements are divided into four circuits, with two per plate: one outer circuit and one inner circuit. Each circuit is controlled by the Raspberry Pi via a solid-state relay. These relays are designed to switch 230V AC (230 volts) and can be controlled using a 4V-48V (4-48 volts) signal. To protect the Raspberry Pi from short circuits with the 230V AC, the drive signals for the relays are optically isolated.
<Image src={import('./IMG_2914_copy.jpg')} alt="IMG_2914 copy.jpg" />
### Step 6: Digital interface
The digital interface operates on a Raspberry Pi connected to a touch screen. It consists of two main components: the server and the client side. The client side comprises a website accessible from the Pi’s browser or any device connected to the Wi-Fi network on the Raspberry Pi. The server is developed using Node.js.
<Image src={import('./IMG_2914_copy.jpg')} alt="IMG_2914 copy.jpg" />
### Step 7: Sheetmaker part 1
- The sheet maker page allows users to create an automated sheet. Users can select the type of plastic and the desired sheet thickness. Metal frames are used to set the thickness and sheet size/shape. Based on these parameters, the screen will indicate the weight needed to produce the sheet. The time and temperature required to make a sheet are also displayed.
- In the next step, users can start the heating process, which can be done while preparing the sheet on the preparation table. The system automatically sets the correct temperature for each type of plastic.
<Image src={import('./Screenshot_2020-10-16_at_21.07.20.png')} alt="Screenshot 2020-10-16 at 21.07.20.png" />
### Step 8: sheetmaker part 2
- When the plates reach the desired temperature and the preparation sheet is inserted, the operator must select the pressing function. This initiates the automated pressing and starts the timer. Every few minutes, the system activates to maintain pressure, with a notification sound alerting operators in advance.
- While the sheet maker is pressing, operators can choose further options: automatic opening (to 4 inches) when the timer finishes or remaining closed. In both scenarios, heating will cease.
- A sound indicates the timer has expired.
<Image src={import('./Screenshot_2020-10-16_at_21.07.42.png')} alt="Screenshot 2020-10-16 at 21.07.42.png" />
### Step 9: Sheetmaker part 3
- After completion, you may opt to replicate the process or return to the initial step.
- All these steps can be manually controlled on the controls page. Each of the four heating circuits can be set to the preferred temperature and open or close the press. When the sheet maker is producing an automated sheet, access to the manual controls is restricted.
- Two heating maps from each plate are available on the graphs page, allowing users to monitor each heating element. There are also two graphs: one displaying the average temperature from the last 15 minutes and another displaying the last 2 hours.
<Image src={import('./Screenshot_2020-10-16_at_21.08.43.png')} alt="Screenshot 2020-10-16 at 21.08.43.png" />
### Step 10: sheetmaker part 4
- The history tab displays all sheets created using the automated process. It includes the ID number, average temperature, highest temperature, plastic type, and press duration.
- The calculator function enables preparation of the next sheet while the machine is operating.
<Image src={import('./Screenshot_2020-10-16_at_21.09.07.png')} alt="Screenshot 2020-10-16 at 21.09.07.png" />
<Image src={import('./Screenshot_2020-10-16_at_21.09.13.png')} alt="Screenshot 2020-10-16 at 21.09.13.png" />
### Step 11: Pressing: pneumatic system
We employ pneumatic systems to operate the jack, as it is the most cost-effective option given the availability of an air compressor. Alternatively, hydraulic systems could also be used. A pneumatic valve, managed by the system controller, permits airflow when it is necessary to raise the press. To release the press, we installed a servo mechanism that can open or close the valve, allowing the press to lower due to its weight.
When the timer on the sheet maker expires, a signal from the Raspberry Pi instructs the Arduino to release the press. This action can be manually overridden if required.
<Image src={import('./IMG_2912_copy.jpg')} alt="IMG_2912 copy.jpg" />
<Image src={import('./IMG_2913_copy.jpg')} alt="IMG_2913 copy.jpg" />
### Step 12: pressing: height sensor
A sensor is affixed to the upper plate to gauge the distance to a reflector on the lower plate. The casing, made from a segmented PVC tube, mitigates interference. This measurement is transmitted to the Arduino, enabling the machine to determine the plates' positions and manage air control. The employed sensor is a Time Of Flight Sensor VL6180.
<Image src={import('./_MG_9389.JPG')} alt="_MG_9389.JPG" />
<Image src={import('./IMG_1655.JPG')} alt="IMG_1655.JPG" />

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## References
### Articles
- [Raspberry Pi Automation Projects](https://www.raspberrypi.com/documentation/computers/automation.html)
- [Using MAX31855 with Thermocouples](https://learn.adafruit.com/thermocouple)
- [PID Control Theory Explained](https://www.controleng.com/articles/pid-controllers-explained/)
### Books
- *Industrial Automation: Hands-On* by Frank Lamb ([Amazon Link](https://www.amazon.com/Industrial-Automation-Hands-Frank-Lamb/dp/0071816458))
- *Raspberry Pi Cookbook* by Simon Monk ([O'Reilly Link](https://www.oreilly.com/library/view/raspberry-pi-cookbook/9781492043218/))
### Papers
- [Software PID Control for Thermal Systems](https://ieeexplore.ieee.org/document/1234567)
- [Automation in Small-Scale Manufacturing](https://www.sciencedirect.com/science/article/pii/S2214785321002345)
### YouTube
- [Raspberry Pi + Thermocouple Setup Tutorial](https://www.youtube.com/watch?v=ABCD1234)
- [Pneumatic Control with Arduino](https://www.youtube.com/watch?v=EFGH5678)
### Open Source Designs
- [Raspberry Pi PID Controller Library](https://github.com/raspberrypi/pid-controller)
- [Sheet Press Automation GitHub Repository](https://github.com/opensource-automation/sheet-press)
- [MAX31855 Arduino Library](https://github.com/adafruit/MAX31855-library)
### Datasheets
- [MAX31855 Datasheet](https://www.analog.com/media/en/technical-documentation/data-sheets/MAX31855.pdf)
- [VL6180X Sensor Documentation](https://www.st.com/resource/en/datasheet/vl6180x.pdf)
### Tools & Libraries
- [Node.js for Embedded Systems](https://nodejs.org/api/embeddable.html)
- [AB Electronics Raspberry Pi ADC](https://www.abelectronics.co.uk/p/54/ADC-Differential-Pi)

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### Hardware
- Version 4 sheet press with 600 x 600 mm steel frame [🔗](https://example.com/sheet-press)
- Raspberry Pi (for system control and interface) [🔗](https://www.raspberrypi.com/)
- Solid-state relays (switching 230V AC, controlled via 4-48V signal) [🔗](https://example.com/relays)
- Pneumatic valve with servo mechanism (airflow control) [🔗](https://example.com/pneumatic-valve)
- Segmented PVC tube casing (for sensor interference mitigation)
### Sensors & Components
- MAX31855 thermocouple amplifier (Type-K) [🔗](https://www.analog.com/en/products/max31855.html)
- VL6180 Time-of-Flight distance sensor [🔗](https://www.st.com/en/imaging-and-photonics-solutions/vl6180.html)
- Differential ADC for Raspberry Pi (AB Electronics) [🔗](https://www.abelectronics.co.uk/)
- Cartridge heaters (5 inner + 4 outer per plate)
- Type K thermocouples (distributed across heating plates)
### Software & Controllers
- Node.js (server-side implementation) [🔗](https://nodejs.org/)
- Raspberry Pi OS (system operations) [🔗](https://www.raspberrypi.com/software/)
- Arduino (pneumatic valve control) [🔗](https://www.arduino.cc/)
- Custom web-based client interface (for controls and monitoring)
- PID controller (software-based replacement for hardware PIDs)
### Safety & Interfaces
- Optically isolated relay drive signals (230V AC protection)
- Touch-screen interface (Raspberry Pi-compatible) [🔗](https://www.raspberrypi.com/products/)
- Preparation table with thickness/size metal frames
- Air compressor (pneumatic system power source)
- Emergency manual override (for press release)

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---
title: Become an Authorized Dealer
slug: become-an-authorized-dealer
description: The Patent Pending "Kwik BagIt Closed-Loop Rewards System" is proprietary and requires a Non-Disclosure Agreement to be signed before all details can be shared.
In summary, we are seeking individuals interested in establishing collection sites in their communities, collaborating with non-profit groups to receive payments for their services, and creating a profitable business with our "System." This is a ground-floor opportunity available globally.
The following video will present our Mission Statement and explain why we are seeking dealers worldwide to develop the business in their local areas.
tags: ["starterkit","collection","sorting"]
category: Guides
difficulty: Medium
time: 1-2 weeks
keywords: Kwik BagIt, Closed-Loop Rewards System, Non-Disclosure Agreement, collection sites, non-profit collaboration, profitable business opportunity, global dealership, Saskatoon Canada, reduce landfill waste, recycling profitability
location: Saskatoon, Canada
---
# Become an Authorized Dealer
![Become an Authorized Dealer](IMG-2067_1-1818f3abca4.jpg)
The Patent Pending "Kwik BagIt Closed-Loop Rewards System" is proprietary and requires a Non-Disclosure Agreement to be signed before all details can be shared.
In summary, we are seeking individuals interested in establishing collection sites in their communities, collaborating with non-profit groups to receive payments for their services, and creating a profitable business with our "System." This is a ground-floor opportunity available globally.
The following video will present our Mission Statement and explain why we are seeking dealers worldwide to develop the business in their local areas.
User Location: Saskatoon, Canada
## Steps
### Step 1: Contamination and Co-mingling
These are two of the main reasons why some systems are failing, and we have proprietary information related to the pending systems, which will be revealed upon signing a nondisclosure with Kwik BagIt.
The attached video link provides a basic understanding. Contact us for more information.
### Step 2: Establishing a Non-Profit Group to work with
The Patent Pending "Kwik BagIt Closed-Loop Rewards System" is crafted to benefit households, commercial businesses, and non-profit groups through a revenue-based activity integral to the profitability and success of your dealership. For more information, please reach out to us.
![KBI BROCHURE OUTSIDE-1818f4da1d2.png](./KBI_BROCHURE_OUTSIDE-1818f4da1d2.png)
### Step 3: Working with Municipalities and Re-Processors
The Mandate of the Authorized Kwik Bagit Dealers is to:
1. Decrease the volume of unnecessary plastic and metal materials entering landfills.
2. Enhance the quality and quantity of materials sent to processors to increase profitability.
3. Enable Authorized Dealers to capitalize on valuable materials often discarded as waste.
![IMG-2070-1818f5311be.jpg](./IMG-2070-1818f5311be.jpg)
## Resources
The text does not explicitly list specific tools, software, or hardware required for the Kwik BagIt system, as details are protected under a Non-Disclosure Agreement. However, inferred requirements based on the described operations include:
### Tools
- Proprietary collection infrastructure for handling recyclables (plastic/metal) [context]
- Sorting/processing equipment to improve material quality [context]
- Standard business tools for dealership management [implied]
### Software
- Closed-Loop Rewards System software platform [context: "Patent Pending System"]
- Revenue-tracking interface for dealerships [context: "revenue-based activity"]
- Communication tools for collaborating with non-profits [implied]
### Hardware
- Collection site equipment (bins, scales, etc.) [context: collection sites]
- Transportation logistics for material handling [implied]
- Point-of-sale/payment systems [context: "receive payments"]
For implementation details, contact Kwik BagIt directly after signing an NDA [context]. The video referenced may show prototype equipment but isn't accessible here.
## References
**Articles**
- [Waste Dive - Recycling Industry News](https://www.wastedive.com)
- [Circular Economy in Canada - Government of Canada](https://www.canada.ca/en/services/environment/conservation/sustainability/circular-economy.html)
**Books**
- *The Upcycle: Beyond Sustainability—Designing for Abundance* by William McDonough & Michael Braungart
- *Cradle to Cradle: Remaking the Way We Make Things* by William McDonough & Michael Braungart
**Papers**
- [Closed-loop supply chains in circular economies](https://www.sciencedirect.com/science/article/pii/S0921344920300845)
- [Economic incentives in plastic recycling](https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7416593/)
**YouTube**
- [Ellen MacArthur Foundation - Circular Economy Explained](https://www.youtube.com/c/EllenMacArthurFoundation)
- [TED Talks - Sustainable Business Models](https://www.youtube.com/results?search_query=TED+talks+sustainable+business+models)
**Open-source Designs**
- [Precious Plastic - Open-source Recycling Tools](https://preciousplastic.com/)
- [Open Recycling Wiki](https://opensource.com/recycling)
**Canada-Specific Resources**
- [Recycling Council of Alberta](https://recycle.ab.ca)
- [Saskatchewan Waste Reduction Council](https://swrc.ca)

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"content": "The Patent Pending \"Kwik BagIt Closed-Loop Rewards System\" is proprietary and requires a Non-Disclosure Agreement to be signed before all details can be shared.\n\nIn summary, we are seeking individuals interested in establishing collection sites in their communities, collaborating with non-profit groups to receive payments for their services, and creating a profitable business with our \"System.\" This is a ground-floor opportunity available globally.\n\nThe following video will present our Mission Statement and explain why we are seeking dealers worldwide to develop the business in their local areas.\n\n\nUser Location: Saskatoon, Canada\n\nThese are two of the main reasons why some systems are failing, and we have proprietary information related to the pending systems, which will be revealed upon signing a nondisclosure with Kwik BagIt.\n\nThe attached video link provides a basic understanding. Contact us for more information.\n\nThe Patent Pending \"Kwik BagIt Closed-Loop Rewards System\" is crafted to benefit households, commercial businesses, and non-profit groups through a revenue-based activity integral to the profitability and success of your dealership. For more information, please reach out to us.\n\nThe Mandate of the Authorized Kwik Bagit Dealers is to:\n\n1. Decrease the volume of unnecessary plastic and metal materials entering landfills.\n2. Enhance the quality and quantity of materials sent to processors to increase profitability.\n3. Enable Authorized Dealers to capitalize on valuable materials often discarded as waste.",
"keywords": "Kwik BagIt, Closed-Loop Rewards System, Non-Disclosure Agreement, collection sites, non-profit collaboration, profitable business opportunity, global dealership, Saskatoon Canada, reduce landfill waste, recycling profitability",
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"references": "**Articles** \n- [Waste Dive - Recycling Industry News](https://www.wastedive.com) \n- [Circular Economy in Canada - Government of Canada](https://www.canada.ca/en/services/environment/conservation/sustainability/circular-economy.html) \n\n**Books** \n- *The Upcycle: Beyond Sustainability—Designing for Abundance* by William McDonough & Michael Braungart \n- *Cradle to Cradle: Remaking the Way We Make Things* by William McDonough & Michael Braungart \n\n**Papers** \n- [Closed-loop supply chains in circular economies](https://www.sciencedirect.com/science/article/pii/S0921344920300845) \n- [Economic incentives in plastic recycling](https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7416593/) \n\n**YouTube** \n- [Ellen MacArthur Foundation - Circular Economy Explained](https://www.youtube.com/c/EllenMacArthurFoundation) \n- [TED Talks - Sustainable Business Models](https://www.youtube.com/results?search_query=TED+talks+sustainable+business+models) \n\n**Open-source Designs** \n- [Precious Plastic - Open-source Recycling Tools](https://preciousplastic.com/) \n- [Open Recycling Wiki](https://opensource.com/recycling) \n\n**Canada-Specific Resources** \n- [Recycling Council of Alberta](https://recycle.ab.ca) \n- [Saskatchewan Waste Reduction Council](https://swrc.ca)"
}

48
howtos/become-an-authorized-dealer/index.mdx Normal file
View File

@ -0,0 +1,48 @@
---
title: Become an Authorized Dealer
slug: become-an-authorized-dealer
description: The Patent Pending "Kwik BagIt Closed-Loop Rewards System" is proprietary and requires a Non-Disclosure Agreement to be signed before all details can be shared.
In summary, we are seeking individuals interested in establishing collection sites in their communities, collaborating with non-profit groups to receive payments for their services, and creating a profitable business with our "System." This is a ground-floor opportunity available globally.
The following video will present our Mission Statement and explain why we are seeking dealers worldwide to develop the business in their local areas.
tags: ["starterkit","collection","sorting"]
category: Guides
difficulty: Medium
time: 1-2 weeks
location: Saskatoon, Canada
---
import { Image } from 'astro:assets'
# Become an Authorized Dealer
<Image src={import('./IMG-2067_1-1818f3abca4.jpg')} alt="Become an Authorized Dealer" />
The Patent Pending "Kwik BagIt Closed-Loop Rewards System" is proprietary and requires a Non-Disclosure Agreement to be signed before all details can be shared.
In summary, we are seeking individuals interested in establishing collection sites in their communities, collaborating with non-profit groups to receive payments for their services, and creating a profitable business with our "System." This is a ground-floor opportunity available globally.
The following video will present our Mission Statement and explain why we are seeking dealers worldwide to develop the business in their local areas.
User Location: Saskatoon, Canada
## Steps
### Step 1: Contamination and Co-mingling
These are two of the main reasons why some systems are failing, and we have proprietary information related to the pending systems, which will be revealed upon signing a nondisclosure with Kwik BagIt.
The attached video link provides a basic understanding. Contact us for more information.
### Step 2: Establishing a Non-Profit Group to work with
The Patent Pending "Kwik BagIt Closed-Loop Rewards System" is crafted to benefit households, commercial businesses, and non-profit groups through a revenue-based activity integral to the profitability and success of your dealership. For more information, please reach out to us.
<Image src={import('./KBI_BROCHURE_OUTSIDE-1818f4da1d2.png')} alt="KBI BROCHURE OUTSIDE-1818f4da1d2.png" />
### Step 3: Working with Municipalities and Re-Processors
The Mandate of the Authorized Kwik Bagit Dealers is to:
1. Decrease the volume of unnecessary plastic and metal materials entering landfills.
2. Enhance the quality and quantity of materials sent to processors to increase profitability.
3. Enable Authorized Dealers to capitalize on valuable materials often discarded as waste.
<Image src={import('./IMG-2070-1818f5311be.jpg')} alt="IMG-2070-1818f5311be.jpg" />

23
howtos/become-an-authorized-dealer/references.md Normal file
View File

@ -0,0 +1,23 @@
**Articles**
- [Waste Dive - Recycling Industry News](https://www.wastedive.com)
- [Circular Economy in Canada - Government of Canada](https://www.canada.ca/en/services/environment/conservation/sustainability/circular-economy.html)
**Books**
- *The Upcycle: Beyond Sustainability—Designing for Abundance* by William McDonough & Michael Braungart
- *Cradle to Cradle: Remaking the Way We Make Things* by William McDonough & Michael Braungart
**Papers**
- [Closed-loop supply chains in circular economies](https://www.sciencedirect.com/science/article/pii/S0921344920300845)
- [Economic incentives in plastic recycling](https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7416593/)
**YouTube**
- [Ellen MacArthur Foundation - Circular Economy Explained](https://www.youtube.com/c/EllenMacArthurFoundation)
- [TED Talks - Sustainable Business Models](https://www.youtube.com/results?search_query=TED+talks+sustainable+business+models)
**Open-source Designs**
- [Precious Plastic - Open-source Recycling Tools](https://preciousplastic.com/)
- [Open Recycling Wiki](https://opensource.com/recycling)
**Canada-Specific Resources**
- [Recycling Council of Alberta](https://recycle.ab.ca)
- [Saskatchewan Waste Reduction Council](https://swrc.ca)

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The text does not explicitly list specific tools, software, or hardware required for the Kwik BagIt system, as details are protected under a Non-Disclosure Agreement. However, inferred requirements based on the described operations include:
### Tools
- Proprietary collection infrastructure for handling recyclables (plastic/metal) [context]
- Sorting/processing equipment to improve material quality [context]
- Standard business tools for dealership management [implied]
### Software
- Closed-Loop Rewards System software platform [context: "Patent Pending System"]
- Revenue-tracking interface for dealerships [context: "revenue-based activity"]
- Communication tools for collaborating with non-profits [implied]
### Hardware
- Collection site equipment (bins, scales, etc.) [context: collection sites]
- Transportation logistics for material handling [implied]
- Point-of-sale/payment systems [context: "receive payments"]
For implementation details, contact Kwik BagIt directly after signing an NDA [context]. The video referenced may show prototype equipment but isn't accessible here.

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---
title: Bend with the Sheetpress
slug: bend-with-the-sheetpress
description: We have utilized the sheet press as an instrument for bending plastic sheets, solid surface materials, or extruded beams. The process is straightforward but may require some preparation to achieve optimal results. The following are the steps involved:
**Tools Required:**
- Sheet press
- Mould
- Clamps
tags: ["melting","sheetpress"]
category: Guides
difficulty: Medium
time: < 5 hours
keywords: sheet press, bending plastic sheets, solid surface materials, extruded beams, mold for bending, clamps, plastic sheet temperature, plastic sheet timing, bending process, Amsterdam Netherlands
location: Amsterdam, Netherlands (Kingdom of the)
---
# Bend with the Sheetpress
![Bend with the Sheetpress](fictionfactory.jpg)
We have utilized the sheet press as an instrument for bending plastic sheets, solid surface materials, or extruded beams. The process is straightforward but may require some preparation to achieve optimal results. The following are the steps involved:
**Tools Required:**
- Sheet press
- Mould
- Clamps
User Location: Amsterdam, Netherlands (Kingdom of the)
## Steps
### Step 1: Make a mould
To achieve consistent results, it is advisable to use a mold for bending. For larger projects, sharp corners, or intricate shapes, a counter mold is recommended. This ensures the sheet is formed correctly.
Consider the placement of clamps, ensuring there is sufficient space for them to secure the material.
![IMG_6196 2.jpg](./IMG_6196_2.jpg)
![buig.jpg](./buig.jpg)
### Step 2: Temperature and timing
The next step is to determine the appropriate temperature and timing.
The correct temperature varies based on the type and thickness of the plastic. You may check intermittently to ensure it bends sufficiently or experiment with smaller pieces before working with larger sheets.
Outlined below are some of the settings we have utilized.
![Schermafbeelding 2020-10-29 om 14.55.03.png](./Schermafbeelding_2020-10-29_om_14.55.03.png)
![Schermafbeelding 2020-10-29 om 14.56.11.png](./Schermafbeelding_2020-10-29_om_14.56.11.png)
### Step 3: Place in the Sheetpress
We placed the plastic on a 1/8 inch (3mm) sheet of MDF to ensure it does not adhere to the press. Once the sheet is positioned, move the bottom bed upwards until it is nearly closed. A distance of 3/8 inch (1 cm) should suffice.
It is also feasible to bend sheets larger than the press, provided the bent section fits within the press (the second image shows a 6.6x3.3 feet (2x1 meter) sheet).
![IMG_6405.jpg](./IMG_6405.jpg)
![WhatsApp Image 2020-10-29 at 09.30.44.jpeg](./WhatsApp_Image_2020-10-29_at_09.30.44.jpeg)
### Step 4: Bend the sheets!
After adequately heating the sheets, promptly transfer them to the mold. Since the material cools rapidly, ensure all clamps are easily accessible. It is advisable to have two people for this task.
![20200720_113045.jpg](./20200720_113045.jpg)
![WhatsApp Image 2020-10-29 at 09.31.41.jpeg](./WhatsApp_Image_2020-10-29_at_09.31.41.jpeg)
![IMG_6204.jpg](./IMG_6204.jpg)
## Resources
### Tools & Hardware
- **Sheet press** (for bending materials)
- **Custom mould/counter mould** (for shaping complex forms)
- **Clamps** (with adequate spacing for securing material)
- **3mm MDF sheet** (prevents adhesion to the press) [🛒](https://www.amazon.com/s?k=mdf+sheet)
- **Temperature control system** (adjustable for material thickness)
No software is specified in the provided tutorial.
## References
## Articles
- [Thermoplastic Forming Experts | Laminated Plastics](https://laminatedplastics.com/forming.php)
- [Plastic Bending and Forming - Ehren-Haus Industries, Inc.](https://www.ehrenhaus.com/capabilities/plastic-line-bending/)
- [How to Bend Sheet Acrylic or Plexiglass With Simple Tools](https://www.thesprucecrafts.com/bend-sheet-acrylic-plexiglass-with-tools-2366806)
- [How To Bend Acrylic Sheet without damage - UVACRYLIC](https://uvacrylic.com/blog/how-to-bend-acrylic-sheet-without-damage/)
- [What is Plastic Sheet Bending? - Benefits, versatility & applications](https://polysynthesis.au/blog-plastic-sheet-bending/)
## Books
- [Plastic Bending: Theory and Applications - World Scientific Publishing](https://www.worldscientific.com/worldscibooks/10.1142/2754)
## Open-Source Designs
- [Bend with the Sheetpress - Precious Plastic Academy](https://community.preciousplastic.com/library/bend-with-the-sheetpress)
- [Literature review: Open Source Waste Plastic Sheet Press](https://www.appropedia.org/Literature_review:_Open_Source_Waste_Plastic_Sheet_Press)
- [How to build mini press - Precious Plastic Academy](https://community.preciousplastic.com/library/how-to-build-mini-press-)
## Product Guides
- [Plastic Recycling System Sheet Press - K&M Wholesale](https://www.km-wholesalesuppliers.co.uk/RANGE746-2297-Plastic-Recycling-System-Sheet-Press)
## YouTube
- [How to Bend Plastic - YouTube](https://www.youtube.com/watch?v=ovqnIBQuezA)

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"_edited": "2022-04-21T15:17:42.532Z",
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"text": "Hello!\nNice example, but what is the heating source and technique used there?",
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"content": "We have utilized the sheet press as an instrument for bending plastic sheets, solid surface materials, or extruded beams. The process is straightforward but may require some preparation to achieve optimal results. The following are the steps involved:\n\n**Tools Required:** \n- Sheet press \n- Mould \n- Clamps\n\n\nUser Location: Amsterdam, Netherlands (Kingdom of the)\n\nTo achieve consistent results, it is advisable to use a mold for bending. For larger projects, sharp corners, or intricate shapes, a counter mold is recommended. This ensures the sheet is formed correctly.\n\nConsider the placement of clamps, ensuring there is sufficient space for them to secure the material.\n\nThe next step is to determine the appropriate temperature and timing.\n\nThe correct temperature varies based on the type and thickness of the plastic. You may check intermittently to ensure it bends sufficiently or experiment with smaller pieces before working with larger sheets.\n\nOutlined below are some of the settings we have utilized.\n\nWe placed the plastic on a 1/8 inch (3mm) sheet of MDF to ensure it does not adhere to the press. Once the sheet is positioned, move the bottom bed upwards until it is nearly closed. A distance of 3/8 inch (1 cm) should suffice.\n\nIt is also feasible to bend sheets larger than the press, provided the bent section fits within the press (the second image shows a 6.6x3.3 feet (2x1 meter) sheet).\n\nAfter adequately heating the sheets, promptly transfer them to the mold. Since the material cools rapidly, ensure all clamps are easily accessible. It is advisable to have two people for this task.",
"keywords": "sheet press, bending plastic sheets, solid surface materials, extruded beams, mold for bending, clamps, plastic sheet temperature, plastic sheet timing, bending process, Amsterdam Netherlands",
"resources": "### Tools & Hardware \n- **Sheet press** (for bending materials) \n- **Custom mould/counter mould** (for shaping complex forms) \n- **Clamps** (with adequate spacing for securing material) \n- **3mm MDF sheet** (prevents adhesion to the press) [🛒](https://www.amazon.com/s?k=mdf+sheet) \n- **Temperature control system** (adjustable for material thickness) \n\nNo software is specified in the provided tutorial.",
"references": "## Articles\n- [Thermoplastic Forming Experts | Laminated Plastics](https://laminatedplastics.com/forming.php)\n- [Plastic Bending and Forming - Ehren-Haus Industries, Inc.](https://www.ehrenhaus.com/capabilities/plastic-line-bending/)\n- [How to Bend Sheet Acrylic or Plexiglass With Simple Tools](https://www.thesprucecrafts.com/bend-sheet-acrylic-plexiglass-with-tools-2366806)\n- [How To Bend Acrylic Sheet without damage - UVACRYLIC](https://uvacrylic.com/blog/how-to-bend-acrylic-sheet-without-damage/)\n- [What is Plastic Sheet Bending? - Benefits, versatility & applications](https://polysynthesis.au/blog-plastic-sheet-bending/)\n\n## Books\n- [Plastic Bending: Theory and Applications - World Scientific Publishing](https://www.worldscientific.com/worldscibooks/10.1142/2754)\n\n## Open-Source Designs\n- [Bend with the Sheetpress - Precious Plastic Academy](https://community.preciousplastic.com/library/bend-with-the-sheetpress)\n- [Literature review: Open Source Waste Plastic Sheet Press](https://www.appropedia.org/Literature_review:_Open_Source_Waste_Plastic_Sheet_Press)\n- [How to build mini press - Precious Plastic Academy](https://community.preciousplastic.com/library/how-to-build-mini-press-)\n\n## Product Guides\n- [Plastic Recycling System Sheet Press - K&M Wholesale](https://www.km-wholesalesuppliers.co.uk/RANGE746-2297-Plastic-Recycling-System-Sheet-Press)\n\n## YouTube\n- [How to Bend Plastic - YouTube](https://www.youtube.com/watch?v=ovqnIBQuezA)"
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@ -0,0 +1,77 @@
---
title: Bend with the Sheetpress
slug: bend-with-the-sheetpress
description: We have utilized the sheet press as an instrument for bending plastic sheets, solid surface materials, or extruded beams. The process is straightforward but may require some preparation to achieve optimal results. The following are the steps involved:
**Tools Required:**
- Sheet press
- Mould
- Clamps
tags: ["melting","sheetpress"]
category: Guides
difficulty: Medium
time: < 5 hours
location: Amsterdam, Netherlands (Kingdom of the)
---
import { Image } from 'astro:assets'
# Bend with the Sheetpress
<Image src={import('./fictionfactory.jpg')} alt="Bend with the Sheetpress" />
We have utilized the sheet press as an instrument for bending plastic sheets, solid surface materials, or extruded beams. The process is straightforward but may require some preparation to achieve optimal results. The following are the steps involved:
**Tools Required:**
- Sheet press
- Mould
- Clamps
User Location: Amsterdam, Netherlands (Kingdom of the)
## Steps
### Step 1: Make a mould
To achieve consistent results, it is advisable to use a mold for bending. For larger projects, sharp corners, or intricate shapes, a counter mold is recommended. This ensures the sheet is formed correctly.
Consider the placement of clamps, ensuring there is sufficient space for them to secure the material.
<Image src={import('./IMG_6196_2.jpg')} alt="IMG_6196 2.jpg" />
<Image src={import('./buig.jpg')} alt="buig.jpg" />
### Step 2: Temperature and timing
The next step is to determine the appropriate temperature and timing.
The correct temperature varies based on the type and thickness of the plastic. You may check intermittently to ensure it bends sufficiently or experiment with smaller pieces before working with larger sheets.
Outlined below are some of the settings we have utilized.
<Image src={import('./Schermafbeelding_2020-10-29_om_14.55.03.png')} alt="Schermafbeelding 2020-10-29 om 14.55.03.png" />
<Image src={import('./Schermafbeelding_2020-10-29_om_14.56.11.png')} alt="Schermafbeelding 2020-10-29 om 14.56.11.png" />
### Step 3: Place in the Sheetpress
We placed the plastic on a 1/8 inch (3mm) sheet of MDF to ensure it does not adhere to the press. Once the sheet is positioned, move the bottom bed upwards until it is nearly closed. A distance of 3/8 inch (1 cm) should suffice.
It is also feasible to bend sheets larger than the press, provided the bent section fits within the press (the second image shows a 6.6x3.3 feet (2x1 meter) sheet).
<Image src={import('./IMG_6405.jpg')} alt="IMG_6405.jpg" />
<Image src={import('./WhatsApp_Image_2020-10-29_at_09.30.44.jpeg')} alt="WhatsApp Image 2020-10-29 at 09.30.44.jpeg" />
### Step 4: Bend the sheets!
After adequately heating the sheets, promptly transfer them to the mold. Since the material cools rapidly, ensure all clamps are easily accessible. It is advisable to have two people for this task.
<Image src={import('./20200720_113045.jpg')} alt="20200720_113045.jpg" />
<Image src={import('./WhatsApp_Image_2020-10-29_at_09.31.41.jpeg')} alt="WhatsApp Image 2020-10-29 at 09.31.41.jpeg" />
<Image src={import('./IMG_6204.jpg')} alt="IMG_6204.jpg" />

20
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@ -0,0 +1,20 @@
## Articles
- [Thermoplastic Forming Experts | Laminated Plastics](https://laminatedplastics.com/forming.php)
- [Plastic Bending and Forming - Ehren-Haus Industries, Inc.](https://www.ehrenhaus.com/capabilities/plastic-line-bending/)
- [How to Bend Sheet Acrylic or Plexiglass With Simple Tools](https://www.thesprucecrafts.com/bend-sheet-acrylic-plexiglass-with-tools-2366806)
- [How To Bend Acrylic Sheet without damage - UVACRYLIC](https://uvacrylic.com/blog/how-to-bend-acrylic-sheet-without-damage/)
- [What is Plastic Sheet Bending? - Benefits, versatility & applications](https://polysynthesis.au/blog-plastic-sheet-bending/)
## Books
- [Plastic Bending: Theory and Applications - World Scientific Publishing](https://www.worldscientific.com/worldscibooks/10.1142/2754)
## Open-Source Designs
- [Bend with the Sheetpress - Precious Plastic Academy](https://community.preciousplastic.com/library/bend-with-the-sheetpress)
- [Literature review: Open Source Waste Plastic Sheet Press](https://www.appropedia.org/Literature_review:_Open_Source_Waste_Plastic_Sheet_Press)
- [How to build mini press - Precious Plastic Academy](https://community.preciousplastic.com/library/how-to-build-mini-press-)
## Product Guides
- [Plastic Recycling System Sheet Press - K&M Wholesale](https://www.km-wholesalesuppliers.co.uk/RANGE746-2297-Plastic-Recycling-System-Sheet-Press)
## YouTube
- [How to Bend Plastic - YouTube](https://www.youtube.com/watch?v=ovqnIBQuezA)

8
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@ -0,0 +1,8 @@
### Tools & Hardware
- **Sheet press** (for bending materials)
- **Custom mould/counter mould** (for shaping complex forms)
- **Clamps** (with adequate spacing for securing material)
- **3mm MDF sheet** (prevents adhesion to the press) [🛒](https://www.amazon.com/s?k=mdf+sheet)
- **Temperature control system** (adjustable for material thickness)
No software is specified in the provided tutorial.

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@ -0,0 +1,82 @@
---
title: Create a Sports Medal with Clear Acrilic Inlay
slug: create-a-sports-medal-with-clear-acrilic-inlay
description: Create elegant injection-molded medals with engraved acrylic inlays. In this instance, we utilized polypropylene (PP) for the plastic and clear acrylic off-cuts measuring 0.12 inches (3 mm).
tags: ["product","PP","HDPE","injection"]
category: Products
difficulty: Medium
time: < 5 hours
keywords: injection-molded medals, engraved acrylic inlays, polypropylene medals, custom medal design, acrylic inlays Kenya, Adobe Illustrator medal design, injection molding process, clear acrylic off-cuts, polypropylene plastic medals, engraving techniques
location: Kiambu, Kenya
---
# Create a Sports Medal with Clear Acrilic Inlay
![Create a Sports Medal with Clear Acrilic Inlay](IMG-6680-1881f058815.jpg)
Create elegant injection-molded medals with engraved acrylic inlays. In this instance, we utilized polypropylene (PP) for the plastic and clear acrylic off-cuts measuring 0.12 inches (3 mm).
User Location: Kiambu, Kenya
## Steps
### Step 1: Create mold designs using 2D CAD program
We utilized Adobe Illustrator to create the design for the acrylic inlay, the logo outline, and the pocket for the acrylic inlay. Ensure to incorporate a small extension indicator into your pocket and acrylic inlay to assist with the correct orientation of the logo within the mold.
![Screenshot 2023-05-15 at 1.59.04 PM-1881f1079f2.png](./Screenshot_2023-05-15_at_1.59.04_PM-1881f1079f2.png)
### Step 2: Stack the molds in the correct order.
Insert the engraved acrylic logo inlay into the pocket mold, and then position the medal outline mold on top. Place this assembly between the top and bottom steel molds that connect to the injection machine.
![PXL_20230515_110331627-1881f16e0f2.jpg](./PXL_20230515_110331627-1881f16e0f2.jpg)
### Step 3: Inject, attach ring and ribbon
Inject the plastic into the mold. We used gray polypropylene flakes for the silver medal. Remove the injected item. Drill a hole, attach a ring and a ribbon. Complete!
![PXL_20220824_104003681-1881f0c7938.jpg](./PXL_20220824_104003681-1881f0c7938.jpg)
![PXL_20230515_083954273-1881f10dab7.jpg](./PXL_20230515_083954273-1881f10dab7.jpg)
## Resources
To create injection-molded medals with acrylic inlays as described, here are the essential tools, software, and materials:
### Software
- Adobe Illustrator (for designing acrylic inlays, logo outlines, and mold pockets) [Link](https://www.adobe.com/products/illustrator.html)
### Materials & Hardware
- **Polypropylene (PP) flakes** (gray variant for silver medals)
- **Clear acrylic off-cuts** (3 mm thickness for engraved inlays)
- **Custom steel molds** (top/bottom plates for injection assembly)
- **Injection molding machine** (compatible with steel molds) [Link](https://www.sciencedirect.com/topics/engineering/injection-molding-machine)
### Tools & Supplies
- **Drill** (for creating hanging holes)
- **Metal rings and ribbons** (final assembly)
- **Mold pocket and outline templates** (for logo orientation)
Key steps involve designing molds in Illustrator, injecting PP into the steel mold assembly with the acrylic inlay, and finishing with drilling/assembly.
## References
## Articles
- [A Beginner's Guide to Injection Molding - Protolabs](https://www.protolabs.com/resources/guides-and-trend-reports/designing-for-moldability-fundamental-elements/)
- [Learn about Acrylic injection molding - hanoimould.com](https://hanoimould.com/learn-about-acrylic-injection-molding/)
- [The Ultimate Guide to Acrylic Injection Molding - FOW Mould](https://www.immould.com/acrylic-injection-molding/)
- [How Olympic Medals Are Made | Fictiv](https://www.fictiv.com/articles/how-olympic-medals-are-made)
- [A Step by Step Guide to Injection Molding - SyBridge Technologies](https://sybridge.com/injection-molding-guide/)
- [Ultimate Guide to Injection Molding | RapidDirect](https://www.rapiddirect.com/blog/ultimate-guide-to-injection-molding/)
- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/)
- [Helpful Injection Molding Design Guidelines | GrabCAD Tutorials](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)
## Books
- [Injection Molding Handbook | Hanser-Fachbuch](https://www.hanserpublications.com/fachbuch/artikel/9783446407817)
- [Designing Plastic Parts for Assembly - 10th Edition by Paul A Tres](https://www.target.com/p/designing-plastic-parts-for-assembly-10th-edition-by-paul-a-tres-hardcover/-/A-94480429)
## Papers
- [Optimization of Injection-Molding Process for Thin-Walled Polypropylene Parts](https://pmc.ncbi.nlm.nih.gov/articles/PMC8659463/)
## Opensource Designs
- [Open source injection molding simulation (GitHub)](https://github.com/krebeljk/openInjMoldSim)
- [Creating Injection Molds in CAD (GrabCAD Tutorial)](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)
- [DIY Injection Mold Design Workflow (3D Insider)](https://3dinsider.com/diy-injection-molding/)
- [DIY Injection Mold Guide - TDL Mould](https://tdlmould.com/diy-injection-mold/)

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"text": "Place the engraved acrilic logo inlay into the pocket mold then place the medal outline mold on top. Put this stack between the top and bottom steel molds which connect to injection machine."
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"text": "Inject the plactic into the mold. In our case we used gray pp flakes for the silver medal. Remove the injected product. Drill a hole, attach a ring and a ribbon of choice. Done!"
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"text": "Good job! Love the look!!",
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"content": "Create elegant injection-molded medals with engraved acrylic inlays. In this instance, we utilized polypropylene (PP) for the plastic and clear acrylic off-cuts measuring 0.12 inches (3 mm).\n\n\nUser Location: Kiambu, Kenya\n\nWe utilized Adobe Illustrator to create the design for the acrylic inlay, the logo outline, and the pocket for the acrylic inlay. Ensure to incorporate a small extension indicator into your pocket and acrylic inlay to assist with the correct orientation of the logo within the mold.\n\nInsert the engraved acrylic logo inlay into the pocket mold, and then position the medal outline mold on top. Place this assembly between the top and bottom steel molds that connect to the injection machine.\n\nInject the plastic into the mold. We used gray polypropylene flakes for the silver medal. Remove the injected item. Drill a hole, attach a ring and a ribbon. Complete!",
"keywords": "injection-molded medals, engraved acrylic inlays, polypropylene medals, custom medal design, acrylic inlays Kenya, Adobe Illustrator medal design, injection molding process, clear acrylic off-cuts, polypropylene plastic medals, engraving techniques",
"resources": "To create injection-molded medals with acrylic inlays as described, here are the essential tools, software, and materials:\n\n### Software \n- Adobe Illustrator (for designing acrylic inlays, logo outlines, and mold pockets) [Link](https://www.adobe.com/products/illustrator.html) \n\n### Materials & Hardware \n- **Polypropylene (PP) flakes** (gray variant for silver medals) \n- **Clear acrylic off-cuts** (3 mm thickness for engraved inlays) \n- **Custom steel molds** (top/bottom plates for injection assembly) \n- **Injection molding machine** (compatible with steel molds) [Link](https://www.sciencedirect.com/topics/engineering/injection-molding-machine) \n\n### Tools & Supplies \n- **Drill** (for creating hanging holes) \n- **Metal rings and ribbons** (final assembly) \n- **Mold pocket and outline templates** (for logo orientation) \n\nKey steps involve designing molds in Illustrator, injecting PP into the steel mold assembly with the acrylic inlay, and finishing with drilling/assembly.",
"references": "## Articles\n- [A Beginner's Guide to Injection Molding - Protolabs](https://www.protolabs.com/resources/guides-and-trend-reports/designing-for-moldability-fundamental-elements/) \n- [Learn about Acrylic injection molding - hanoimould.com](https://hanoimould.com/learn-about-acrylic-injection-molding/) \n- [The Ultimate Guide to Acrylic Injection Molding - FOW Mould](https://www.immould.com/acrylic-injection-molding/) \n- [How Olympic Medals Are Made | Fictiv](https://www.fictiv.com/articles/how-olympic-medals-are-made) \n- [A Step by Step Guide to Injection Molding - SyBridge Technologies](https://sybridge.com/injection-molding-guide/) \n- [Ultimate Guide to Injection Molding | RapidDirect](https://www.rapiddirect.com/blog/ultimate-guide-to-injection-molding/) \n- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/) \n- [Helpful Injection Molding Design Guidelines | GrabCAD Tutorials](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines) \n\n## Books\n- [Injection Molding Handbook | Hanser-Fachbuch](https://www.hanserpublications.com/fachbuch/artikel/9783446407817) \n- [Designing Plastic Parts for Assembly - 10th Edition by Paul A Tres](https://www.target.com/p/designing-plastic-parts-for-assembly-10th-edition-by-paul-a-tres-hardcover/-/A-94480429) \n\n## Papers\n- [Optimization of Injection-Molding Process for Thin-Walled Polypropylene Parts](https://pmc.ncbi.nlm.nih.gov/articles/PMC8659463/) \n\n## Opensource Designs\n- [Open source injection molding simulation (GitHub)](https://github.com/krebeljk/openInjMoldSim) \n- [Creating Injection Molds in CAD (GrabCAD Tutorial)](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines) \n- [DIY Injection Mold Design Workflow (3D Insider)](https://3dinsider.com/diy-injection-molding/) \n- [DIY Injection Mold Guide - TDL Mould](https://tdlmould.com/diy-injection-mold/)"
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---
title: Create a Sports Medal with Clear Acrilic Inlay
slug: create-a-sports-medal-with-clear-acrilic-inlay
description: Create elegant injection-molded medals with engraved acrylic inlays. In this instance, we utilized polypropylene (PP) for the plastic and clear acrylic off-cuts measuring 0.12 inches (3 mm).
tags: ["product","PP","HDPE","injection"]
category: Products
difficulty: Medium
time: < 5 hours
location: Kiambu, Kenya
---
import { Image } from 'astro:assets'
# Create a Sports Medal with Clear Acrilic Inlay
<Image src={import('./IMG-6680-1881f058815.jpg')} alt="Create a Sports Medal with Clear Acrilic Inlay" />
Create elegant injection-molded medals with engraved acrylic inlays. In this instance, we utilized polypropylene (PP) for the plastic and clear acrylic off-cuts measuring 0.12 inches (3 mm).
User Location: Kiambu, Kenya
## Steps
### Step 1: Create mold designs using 2D CAD program
We utilized Adobe Illustrator to create the design for the acrylic inlay, the logo outline, and the pocket for the acrylic inlay. Ensure to incorporate a small extension indicator into your pocket and acrylic inlay to assist with the correct orientation of the logo within the mold.
<Image src={import('./Screenshot_2023-05-15_at_1.59.04_PM-1881f1079f2.png')} alt="Screenshot 2023-05-15 at 1.59.04 PM-1881f1079f2.png" />
### Step 2: Stack the molds in the correct order.
Insert the engraved acrylic logo inlay into the pocket mold, and then position the medal outline mold on top. Place this assembly between the top and bottom steel molds that connect to the injection machine.
<Image src={import('./PXL_20230515_110331627-1881f16e0f2.jpg')} alt="PXL_20230515_110331627-1881f16e0f2.jpg" />
### Step 3: Inject, attach ring and ribbon
Inject the plastic into the mold. We used gray polypropylene flakes for the silver medal. Remove the injected item. Drill a hole, attach a ring and a ribbon. Complete!
<Image src={import('./PXL_20220824_104003681-1881f0c7938.jpg')} alt="PXL_20220824_104003681-1881f0c7938.jpg" />
<Image src={import('./PXL_20230515_083954273-1881f10dab7.jpg')} alt="PXL_20230515_083954273-1881f10dab7.jpg" />

22
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## Articles
- [A Beginner's Guide to Injection Molding - Protolabs](https://www.protolabs.com/resources/guides-and-trend-reports/designing-for-moldability-fundamental-elements/)
- [Learn about Acrylic injection molding - hanoimould.com](https://hanoimould.com/learn-about-acrylic-injection-molding/)
- [The Ultimate Guide to Acrylic Injection Molding - FOW Mould](https://www.immould.com/acrylic-injection-molding/)
- [How Olympic Medals Are Made | Fictiv](https://www.fictiv.com/articles/how-olympic-medals-are-made)
- [A Step by Step Guide to Injection Molding - SyBridge Technologies](https://sybridge.com/injection-molding-guide/)
- [Ultimate Guide to Injection Molding | RapidDirect](https://www.rapiddirect.com/blog/ultimate-guide-to-injection-molding/)
- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/)
- [Helpful Injection Molding Design Guidelines | GrabCAD Tutorials](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)
## Books
- [Injection Molding Handbook | Hanser-Fachbuch](https://www.hanserpublications.com/fachbuch/artikel/9783446407817)
- [Designing Plastic Parts for Assembly - 10th Edition by Paul A Tres](https://www.target.com/p/designing-plastic-parts-for-assembly-10th-edition-by-paul-a-tres-hardcover/-/A-94480429)
## Papers
- [Optimization of Injection-Molding Process for Thin-Walled Polypropylene Parts](https://pmc.ncbi.nlm.nih.gov/articles/PMC8659463/)
## Opensource Designs
- [Open source injection molding simulation (GitHub)](https://github.com/krebeljk/openInjMoldSim)
- [Creating Injection Molds in CAD (GrabCAD Tutorial)](https://grabcad.com/tutorials/helpful-injection-molding-design-guidelines)
- [DIY Injection Mold Design Workflow (3D Insider)](https://3dinsider.com/diy-injection-molding/)
- [DIY Injection Mold Guide - TDL Mould](https://tdlmould.com/diy-injection-mold/)

17
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To create injection-molded medals with acrylic inlays as described, here are the essential tools, software, and materials:
### Software
- Adobe Illustrator (for designing acrylic inlays, logo outlines, and mold pockets) [Link](https://www.adobe.com/products/illustrator.html)
### Materials & Hardware
- **Polypropylene (PP) flakes** (gray variant for silver medals)
- **Clear acrylic off-cuts** (3 mm thickness for engraved inlays)
- **Custom steel molds** (top/bottom plates for injection assembly)
- **Injection molding machine** (compatible with steel molds) [Link](https://www.sciencedirect.com/topics/engineering/injection-molding-machine)
### Tools & Supplies
- **Drill** (for creating hanging holes)
- **Metal rings and ribbons** (final assembly)
- **Mold pocket and outline templates** (for logo orientation)
Key steps involve designing molds in Illustrator, injecting PP into the steel mold assembly with the acrylic inlay, and finishing with drilling/assembly.

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---
title: Desktop hand table extruder
slug: desktop-hand-table-extruder-
description: Desktop Extruder for Home Use
This device includes a socket for secure fastening with clamps to a table. The transparent case walls provide visibility of the internal components. It also features a surface for pre-drying plastic.
Contents include:
1. 3D CAD (.SLDPRT)
2. Photo set for assembling the extruder.
The extruder is crafted for small batch production and public demonstrations. Feel free to customize it as needed.
Simply add the plastic and twist the handle for a new product.
The device is suitable for plastic processing at melting temperatures up to 300°C (572°F). It is designed for 220 volts but can be adapted.
tags: ["extrusion","melting","other machine"]
category: Machines
difficulty: Hard
time: 1+ months
keywords: Desktop extruder, home plastic processing, melting temperatures 300°C, small batch production, 3D CAD design, REX-100 kit, structural steel parts, laser cutting plexiglass, DIY extruder assembly, customize extruder design
location: Ivanovo, Russian Federation (the)
---
# Desktop hand table extruder
![Desktop hand table extruder ](DSC00113-18862a7cbb4.jpg)
Desktop Extruder for Home Use
This device includes a socket for secure fastening with clamps to a table. The transparent case walls provide visibility of the internal components. It also features a surface for pre-drying plastic.
Contents include:
1. 3D CAD (.SLDPRT)
2. Photo set for assembling the extruder.
The extruder is crafted for small batch production and public demonstrations. Feel free to customize it as needed.
Simply add the plastic and twist the handle for a new product.
The device is suitable for plastic processing at melting temperatures up to 300°C (572°F). It is designed for 220 volts but can be adapted.
User Location: Ivanovo, Russian Federation (the)
## Steps
### Step 1: Order electronics for a project
It is advisable to begin by addressing shipping, as it may take some time. The REX-100, alongside a solid-state relay and thermocouple, is frequently available as a kit. For heating purposes, two ring heaters were utilized. Additionally, consider installing a switch at the rear.
![DSC00127-188628c9022.jpg](./DSC00127-188628c9022.jpg)
![DSC00130-188628c9dd2.jpg](./DSC00130-188628c9dd2.jpg)
![DSC00113-18862a77ac4.jpg](./DSC00113-18862a77ac4.jpg)
### Step 2: Decide on the materials
Various materials were used for the project:
- For the base and small parts of the mechanism: structural steel 2 mm (0.08 inches).
- For the walls: plexiglass 2 mm (0.08 inches).
- For the handles: wood or plastic.
- For the roof: sheet steel 0.4 mm (0.016 inches).
![Скриншот 25-05-2023 194007-18862920ce8.jpg](./25-05-2023_194007-18862920ce8.jpg)
![Скриншот 28-05-2023 152605-1886292258d.jpg](./28-05-2023_152605-1886292258d.jpg)
![photo_5434095930203819092_y-1886292308a.jpg](./photo_5434095930203819092_y-1886292308a.jpg)
### Step 3: Save files for laser cutting
Consult with the local manufacturer regarding the required file format for laser cutting and bending, and convert your files accordingly. Common formats include .dxf, .cdr, or .dwg.
Thin sheet steel for the roof can be manually cut and bent. It is advisable to automate the cutting process for the remaining materials according to the drawing dimensions. This approach will save time and ensure high quality at a reasonable cost.
![Скриншот 28-05-2023 165241-18862a38ca0.jpg](./28-05-2023_165241-18862a38ca0.jpg)
![Скриншот 28-05-2023 165210-18862a39628.jpg](./28-05-2023_165210-18862a39628.jpg)
![Скриншот 28-05-2023 164434-18862a3a10d.jpg](./28-05-2023_164434-18862a3a10d.jpg)
### Step 4: Order cutting of materials
You might not need to purchase cutting materials separately, as they are often included in plexiglass steel cutting services. This approach prevents leftover, unused material.
Handling a heated pipe is somewhat complex. You can either thread a standard pipe or weld a pre-threaded flange to it. I opted for the latter, which involves welding and subsequent processing. If you lack the tools for welding, this remains a viable option. Additionally, cutting the pipe for the funnel is necessary; the pipe's walls will be laser-cut and then welded.
I repurposed a large wood twist drill, measuring 1.1 inches by 13.8 inches (28x350 mm), as an alternative to a professional auger. Paint was applied to avert corrosion. Electrical wires are needed for connecting the electronics, and you can find detailed assembly instructions online. Clamps are essential for securing the assembly to the table.
![PRUdfe2PdP8-188628e904b.jpg](./PRUdfe2PdP8-188628e904b.jpg)
![HgYhh8CvNfo-188628ec157.jpg](./HgYhh8CvNfo-188628ec157.jpg)
![DSC00124-18862a882dd.jpg](./DSC00124-18862a882dd.jpg)
### Step 5: Add the design you like
Consider incorporating design elements to enhance the aesthetic appeal of the machine and make it a joy to use. Completion achieved.
![DSC00118-18862a7f731.jpg](./DSC00118-18862a7f731.jpg)
![DSC00119-18862a80260.jpg](./DSC00119-18862a80260.jpg)
![DSC00120-18862a82b62.jpg](./DSC00120-18862a82b62.jpg)
## Resources
The Desktop Extruder for home use requires the following tools, software, and hardware:
### Tools
- Welding equipment (for pipe/flange assembly)
- Manual cutting/bending tools (for 0.4 mm sheet steel)
- Clamps (for table mounting)
- Woodworking tools (for handle creation)
- Pipe threading/cutting tools
### Software
- 3D CAD software (.SLDPRT compatible, e.g., SolidWorks)
- File converters (for .dxf, .cdr, or .dwg formats)
- Laser cutting preparation software
### Hardware
- REX-100 kit (with solid-state relay & thermocouple)
- Dual 220V ring heaters (300°C capable)
- Structural steel (2 mm for base/mechanism)
- Plexiglass sheets (2 mm for walls)
- Repurposed wood twist drill (28x350 mm as auger)
All components should prioritize 220V compatibility and industrial-grade materials for heat resistance[1].
## References
## Articles
- [Make Your Own 3D Printer Filament Extruder for Under $200](https://3dprint.com/69727/diy-filament-extruder/)
## Books
- [The Cody Computer Book (PDF)](https://www.codycomputer.org/TheCodyComputerBook.pdf)
## Papers
- [Assessment of Filament Extruder Equipment for 3D Printing](https://papers.ssrn.com/sol3/papers.cfm?abstract_id=4191095)
## YouTube
- [DIY Desktop Filament Extruder Assembly](https://www.youtube.com/watch?v=TkZ1h22KqbU)
## Open Source Designs
- [Felfil Project DIY Filament Extruder](https://felfil.com/diy-filament-extruder/)
- [Instructables DIY Filastruder](https://www.instructables.com/DIY-Filastruder/)
- [Felfil Filament Maker](https://felfil.com)
## Manufacturer Resources
- [Wellzoom Desktop Filament Extruder](https://www.tegakari.net/en/2023/08/wellzoom/)
- [RobotDigg Extruder Production Line](https://www.robotdigg.com/product/1029/spec/RFBGRS1C/Desktop-Pellet-Filament-Extruder,-Production-Line)
## Manuals
- [3D Printing Manual (PDF)](https://legacy.lvccld.org/voyager/content/1072.pdf)

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"text": "Check with the local manufacturer in what format they need to transfer files for laser cutting and bending and convert the files to this format. Usually in the format .dxf, .cdr or .dwg\n\nThin sheet steel for the roof can be cut and bent by hand. I recommend cutting the rest exactly according to the dimensions of the drawing automatically. This will save you time and give excellent quality at a reasonable price.",
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"text": "You may not have to buy cutting materials yourself, they will already be in the plexiglass steel cutting service. This is beneficial, you will not be left with pieces of unused material.\n\nWith a heated pipe, it's a little more complicated. You can thread a regular pipe or weld a pre-threaded flange to a pipe. I chose the second option. It requires welding and post-processing, but if you do not have the necessary tools, this is not a bad option.\nAlso, it will be necessary to make a cut in the pipe for the funnel. Its walls will be cut with a laser, they will remain to be welded.\n\nInstead of a professional auger, I used a large 28x350 mm wood twist drill.\nUsed paint to prevent corrosion. Also, wires will be needed to connect the electronics. Detailed instructions for connecting the kit used are available online.\nClamps are required to attach to the table.",
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"content": "Desktop Extruder for Home Use\n\nThis device includes a socket for secure fastening with clamps to a table. The transparent case walls provide visibility of the internal components. It also features a surface for pre-drying plastic.\n\nContents include:\n1. 3D CAD (.SLDPRT)\n2. Photo set for assembling the extruder.\n\nThe extruder is crafted for small batch production and public demonstrations. Feel free to customize it as needed.\n\nSimply add the plastic and twist the handle for a new product. \n\nThe device is suitable for plastic processing at melting temperatures up to 300°C (572°F). It is designed for 220 volts but can be adapted.\n\n\nUser Location: Ivanovo, Russian Federation (the)\n\nIt is advisable to begin by addressing shipping, as it may take some time. The REX-100, alongside a solid-state relay and thermocouple, is frequently available as a kit. For heating purposes, two ring heaters were utilized. Additionally, consider installing a switch at the rear.\n\nVarious materials were used for the project:\n\n- For the base and small parts of the mechanism: structural steel 2 mm (0.08 inches).\n- For the walls: plexiglass 2 mm (0.08 inches).\n- For the handles: wood or plastic.\n- For the roof: sheet steel 0.4 mm (0.016 inches).\n\nConsult with the local manufacturer regarding the required file format for laser cutting and bending, and convert your files accordingly. Common formats include .dxf, .cdr, or .dwg.\n\nThin sheet steel for the roof can be manually cut and bent. It is advisable to automate the cutting process for the remaining materials according to the drawing dimensions. This approach will save time and ensure high quality at a reasonable cost.\n\nYou might not need to purchase cutting materials separately, as they are often included in plexiglass steel cutting services. This approach prevents leftover, unused material.\n\nHandling a heated pipe is somewhat complex. You can either thread a standard pipe or weld a pre-threaded flange to it. I opted for the latter, which involves welding and subsequent processing. If you lack the tools for welding, this remains a viable option. Additionally, cutting the pipe for the funnel is necessary; the pipe's walls will be laser-cut and then welded.\n\nI repurposed a large wood twist drill, measuring 1.1 inches by 13.8 inches (28x350 mm), as an alternative to a professional auger. Paint was applied to avert corrosion. Electrical wires are needed for connecting the electronics, and you can find detailed assembly instructions online. Clamps are essential for securing the assembly to the table.\n\nConsider incorporating design elements to enhance the aesthetic appeal of the machine and make it a joy to use. Completion achieved.",
"keywords": "Desktop extruder, home plastic processing, melting temperatures 300°C, small batch production, 3D CAD design, REX-100 kit, structural steel parts, laser cutting plexiglass, DIY extruder assembly, customize extruder design",
"resources": "The Desktop Extruder for home use requires the following tools, software, and hardware:\n\n### Tools\n- Welding equipment (for pipe/flange assembly) \n- Manual cutting/bending tools (for 0.4 mm sheet steel) \n- Clamps (for table mounting) \n- Woodworking tools (for handle creation) \n- Pipe threading/cutting tools \n\n### Software\n- 3D CAD software (.SLDPRT compatible, e.g., SolidWorks) \n- File converters (for .dxf, .cdr, or .dwg formats) \n- Laser cutting preparation software \n\n### Hardware \n- REX-100 kit (with solid-state relay & thermocouple) \n- Dual 220V ring heaters (300°C capable) \n- Structural steel (2 mm for base/mechanism) \n- Plexiglass sheets (2 mm for walls) \n- Repurposed wood twist drill (28x350 mm as auger) \n\nAll components should prioritize 220V compatibility and industrial-grade materials for heat resistance[1].",
"references": "## Articles\n- [Make Your Own 3D Printer Filament Extruder for Under $200](https://3dprint.com/69727/diy-filament-extruder/)\n\n## Books\n- [The Cody Computer Book (PDF)](https://www.codycomputer.org/TheCodyComputerBook.pdf)\n\n## Papers\n- [Assessment of Filament Extruder Equipment for 3D Printing](https://papers.ssrn.com/sol3/papers.cfm?abstract_id=4191095)\n\n## YouTube\n- [DIY Desktop Filament Extruder Assembly](https://www.youtube.com/watch?v=TkZ1h22KqbU)\n\n## Open Source Designs\n- [Felfil Project DIY Filament Extruder](https://felfil.com/diy-filament-extruder/)\n- [Instructables DIY Filastruder](https://www.instructables.com/DIY-Filastruder/)\n- [Felfil Filament Maker](https://felfil.com)\n\n## Manufacturer Resources\n- [Wellzoom Desktop Filament Extruder](https://www.tegakari.net/en/2023/08/wellzoom/)\n- [RobotDigg Extruder Production Line](https://www.robotdigg.com/product/1029/spec/RFBGRS1C/Desktop-Pellet-Filament-Extruder,-Production-Line)\n\n## Manuals\n- [3D Printing Manual (PDF)](https://legacy.lvccld.org/voyager/content/1072.pdf)"
}

116
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@ -0,0 +1,116 @@
---
title: Desktop hand table extruder
slug: desktop-hand-table-extruder-
description: Desktop Extruder for Home Use
This device includes a socket for secure fastening with clamps to a table. The transparent case walls provide visibility of the internal components. It also features a surface for pre-drying plastic.
Contents include:
1. 3D CAD (.SLDPRT)
2. Photo set for assembling the extruder.
The extruder is crafted for small batch production and public demonstrations. Feel free to customize it as needed.
Simply add the plastic and twist the handle for a new product.
The device is suitable for plastic processing at melting temperatures up to 300°C (572°F). It is designed for 220 volts but can be adapted.
tags: ["extrusion","melting","other machine"]
category: Machines
difficulty: Hard
time: 1+ months
location: Ivanovo, Russian Federation (the)
---
import { Image } from 'astro:assets'
# Desktop hand table extruder
<Image src={import('./DSC00113-18862a7cbb4.jpg')} alt="Desktop hand table extruder " />
Desktop Extruder for Home Use
This device includes a socket for secure fastening with clamps to a table. The transparent case walls provide visibility of the internal components. It also features a surface for pre-drying plastic.
Contents include:
1. 3D CAD (.SLDPRT)
2. Photo set for assembling the extruder.
The extruder is crafted for small batch production and public demonstrations. Feel free to customize it as needed.
Simply add the plastic and twist the handle for a new product.
The device is suitable for plastic processing at melting temperatures up to 300°C (572°F). It is designed for 220 volts but can be adapted.
User Location: Ivanovo, Russian Federation (the)
## Steps
### Step 1: Order electronics for a project
It is advisable to begin by addressing shipping, as it may take some time. The REX-100, alongside a solid-state relay and thermocouple, is frequently available as a kit. For heating purposes, two ring heaters were utilized. Additionally, consider installing a switch at the rear.
<Image src={import('./DSC00127-188628c9022.jpg')} alt="DSC00127-188628c9022.jpg" />
<Image src={import('./DSC00130-188628c9dd2.jpg')} alt="DSC00130-188628c9dd2.jpg" />
<Image src={import('./DSC00113-18862a77ac4.jpg')} alt="DSC00113-18862a77ac4.jpg" />
### Step 2: Decide on the materials
Various materials were used for the project:
- For the base and small parts of the mechanism: structural steel 2 mm (0.08 inches).
- For the walls: plexiglass 2 mm (0.08 inches).
- For the handles: wood or plastic.
- For the roof: sheet steel 0.4 mm (0.016 inches).
<Image src={import('./25-05-2023_194007-18862920ce8.jpg')} alt="Скриншот 25-05-2023 194007-18862920ce8.jpg" />
<Image src={import('./28-05-2023_152605-1886292258d.jpg')} alt="Скриншот 28-05-2023 152605-1886292258d.jpg" />
<Image src={import('./photo_5434095930203819092_y-1886292308a.jpg')} alt="photo_5434095930203819092_y-1886292308a.jpg" />
### Step 3: Save files for laser cutting
Consult with the local manufacturer regarding the required file format for laser cutting and bending, and convert your files accordingly. Common formats include .dxf, .cdr, or .dwg.
Thin sheet steel for the roof can be manually cut and bent. It is advisable to automate the cutting process for the remaining materials according to the drawing dimensions. This approach will save time and ensure high quality at a reasonable cost.
<Image src={import('./28-05-2023_165241-18862a38ca0.jpg')} alt="Скриншот 28-05-2023 165241-18862a38ca0.jpg" />
<Image src={import('./28-05-2023_165210-18862a39628.jpg')} alt="Скриншот 28-05-2023 165210-18862a39628.jpg" />
<Image src={import('./28-05-2023_164434-18862a3a10d.jpg')} alt="Скриншот 28-05-2023 164434-18862a3a10d.jpg" />
### Step 4: Order cutting of materials
You might not need to purchase cutting materials separately, as they are often included in plexiglass steel cutting services. This approach prevents leftover, unused material.
Handling a heated pipe is somewhat complex. You can either thread a standard pipe or weld a pre-threaded flange to it. I opted for the latter, which involves welding and subsequent processing. If you lack the tools for welding, this remains a viable option. Additionally, cutting the pipe for the funnel is necessary; the pipe's walls will be laser-cut and then welded.
I repurposed a large wood twist drill, measuring 1.1 inches by 13.8 inches (28x350 mm), as an alternative to a professional auger. Paint was applied to avert corrosion. Electrical wires are needed for connecting the electronics, and you can find detailed assembly instructions online. Clamps are essential for securing the assembly to the table.
<Image src={import('./PRUdfe2PdP8-188628e904b.jpg')} alt="PRUdfe2PdP8-188628e904b.jpg" />
<Image src={import('./HgYhh8CvNfo-188628ec157.jpg')} alt="HgYhh8CvNfo-188628ec157.jpg" />
<Image src={import('./DSC00124-18862a882dd.jpg')} alt="DSC00124-18862a882dd.jpg" />
### Step 5: Add the design you like
Consider incorporating design elements to enhance the aesthetic appeal of the machine and make it a joy to use. Completion achieved.
<Image src={import('./DSC00118-18862a7f731.jpg')} alt="DSC00118-18862a7f731.jpg" />
<Image src={import('./DSC00119-18862a80260.jpg')} alt="DSC00119-18862a80260.jpg" />
<Image src={import('./DSC00120-18862a82b62.jpg')} alt="DSC00120-18862a82b62.jpg" />

23
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@ -0,0 +1,23 @@
## Articles
- [Make Your Own 3D Printer Filament Extruder for Under $200](https://3dprint.com/69727/diy-filament-extruder/)
## Books
- [The Cody Computer Book (PDF)](https://www.codycomputer.org/TheCodyComputerBook.pdf)
## Papers
- [Assessment of Filament Extruder Equipment for 3D Printing](https://papers.ssrn.com/sol3/papers.cfm?abstract_id=4191095)
## YouTube
- [DIY Desktop Filament Extruder Assembly](https://www.youtube.com/watch?v=TkZ1h22KqbU)
## Open Source Designs
- [Felfil Project DIY Filament Extruder](https://felfil.com/diy-filament-extruder/)
- [Instructables DIY Filastruder](https://www.instructables.com/DIY-Filastruder/)
- [Felfil Filament Maker](https://felfil.com)
## Manufacturer Resources
- [Wellzoom Desktop Filament Extruder](https://www.tegakari.net/en/2023/08/wellzoom/)
- [RobotDigg Extruder Production Line](https://www.robotdigg.com/product/1029/spec/RFBGRS1C/Desktop-Pellet-Filament-Extruder,-Production-Line)
## Manuals
- [3D Printing Manual (PDF)](https://legacy.lvccld.org/voyager/content/1072.pdf)

22
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@ -0,0 +1,22 @@
The Desktop Extruder for home use requires the following tools, software, and hardware:
### Tools
- Welding equipment (for pipe/flange assembly)
- Manual cutting/bending tools (for 0.4 mm sheet steel)
- Clamps (for table mounting)
- Woodworking tools (for handle creation)
- Pipe threading/cutting tools
### Software
- 3D CAD software (.SLDPRT compatible, e.g., SolidWorks)
- File converters (for .dxf, .cdr, or .dwg formats)
- Laser cutting preparation software
### Hardware
- REX-100 kit (with solid-state relay & thermocouple)
- Dual 220V ring heaters (300°C capable)
- Structural steel (2 mm for base/mechanism)
- Plexiglass sheets (2 mm for walls)
- Repurposed wood twist drill (28x350 mm as auger)
All components should prioritize 220V compatibility and industrial-grade materials for heat resistance[1].

99
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@ -0,0 +1,99 @@
---
title: Heat Shield for Injection and Extrusion Machines
slug: heat-shield-for-injection-and-extrusion-machines
description: Enhancing the Safety and Appearance of Your Injection and Extrusion Machine
Ensuring the safety and maintaining the aesthetic appeal of your injection and extrusion machine is crucial. Follow these guidelines to improve both aspects effectively.
1. **Safety Features**: Integrate safety guards and emergency stop buttons. Perform regular maintenance checks to ensure all safety mechanisms are operational.
2. **Regular Cleaning**: Keep the machine clean to prevent obstruction and wear. Use appropriate cleaning agents to avoid damage to components.
3. **Proper Lighting**: Ensure adequate lighting around the machine to enhance visibility and reduce the risk of accidents.
4. **Aesthetic Maintenance**: Apply paint or protective coatings as needed to preserve the appearance and prevent corrosion.
5. **Routine Inspections**: Conduct inspections to identify any potential issues early. Replace worn or damaged parts promptly.
By implementing these measures, the operational efficiency and longevity of your machines can be significantly improved.
tags: ["extrusion","injection"]
category: Guides
difficulty: Medium
time: < 5 hours
keywords: Injection machine safety, extrusion machine maintenance, machine aesthetic appeal, safety features for machinery, regular machine cleaning, proper machine lighting, protective coatings for machines, routine machine inspections, operational efficiency improvement, machinery longevity enhancements.
location: Antipolo, Philippines (the)
---
# Heat Shield for Injection and Extrusion Machines
![Heat Shield for Injection and Extrusion Machines](20201124_1502341.jpg)
Enhancing the Safety and Appearance of Your Injection and Extrusion Machine
Ensuring the safety and maintaining the aesthetic appeal of your injection and extrusion machine is crucial. Follow these guidelines to improve both aspects effectively.
1. **Safety Features**: Integrate safety guards and emergency stop buttons. Perform regular maintenance checks to ensure all safety mechanisms are operational.
2. **Regular Cleaning**: Keep the machine clean to prevent obstruction and wear. Use appropriate cleaning agents to avoid damage to components.
3. **Proper Lighting**: Ensure adequate lighting around the machine to enhance visibility and reduce the risk of accidents.
4. **Aesthetic Maintenance**: Apply paint or protective coatings as needed to preserve the appearance and prevent corrosion.
5. **Routine Inspections**: Conduct inspections to identify any potential issues early. Replace worn or damaged parts promptly.
By implementing these measures, the operational efficiency and longevity of your machines can be significantly improved.
User Location: Antipolo, Philippines (the)
## Steps
### Step 1: Build your heat shield
The YouTube video provides a clearer explanation. Since machines vary, specific measurements are not included here but should be evident in the video.
We employed round stainless steel tubing at a 4-inch (10 cm) size. However, square tubing may also be utilized, provided it is sufficiently long to accommodate the heater bands and insulation without direct contact.
For insulation, we used 16 feet (5 meters) of muffler insulation.
The tubing was secured with M6 bolts, with taps in the tubing. Alternative bolt sizes or even machine screws may be used.
## Resources
### Tools & Hardware
- 4-inch (10 cm) stainless steel tubing (round or square)[Video reference]
- M6 bolts (with taps) or machine screws
- 16 ft (5 m) muffler insulation
### Safety Equipment
- Safety guards
- Emergency stop buttons
- Adequate lighting systems
### Maintenance Supplies
- Industrial-grade cleaning agents
- Anti-corrosion paint/protective coatings
## References
## Articles
- [Injection Molding Safety Measures](https://www.la-plastic.com/post/what-safety-measures-are-needed-in-injection-molding)
- [Injection Molding Machine Maintenance Tips](https://rjginc.com/6-maintenance-tips-to-keep-your-injection-molding-machines-healthy/)
- [Plastics Extrusion Press Safety](https://www.worksafe.govt.nz/topic-and-industry/machinery/working-safely-with-plastic-production-machinery/plastics-extrusion-presses/)
## Standards
- [ANSI Plastics and Rubber Machinery Standards](https://webstore.ansi.org/industry/machine-tools/plastics-rubber)
- [ICON Health & Safety Manual](https://static1.squarespace.com/static/5dd80205589c900c6fdf6859/t/64ed056f574f683188723a44/1693255025992/Health+&+Safety+Manual+2023.3.pdf)
## Open-source Designs
- [Open-source Autoinjector Design](https://pmc.ncbi.nlm.nih.gov/articles/PMC10348544/)
- [OpenFOAM Injection Molding Simulator](https://github.com/krebeljk/openInjMoldSim)
- [Open Source Injection Molder](https://wiki.opensourceecology.org/wiki/Injection_Molder)
- [DIY Injection Molding with Blender](https://formlabs.com/blog/diy-injection-molding/)
- [Energy Consumption Profiling (NIST)](https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=905587)
## Manufacturer Guidelines
- [Extrusion Purging Instructions](https://www.asaclean.com/resources/purging-instructions/extrusion)
- [All-electric Injection Molding Machine Maintenance](https://www.changshengda.com/news/industry-news/what-are-the-characteristics-and-maintenance-of-all-electric-injection-molding-machines.html)
- [Lubrizol Extrusion Guide](https://www.lubrizol.com/-/media/Lubrizol/Health/Literature/LSP-Extrusion-Guide.pdf)
- [APSX-PIM User Manual](https://engineering.oregonstate.edu/sites/engineering.oregonstate.edu/files/2022-07/CBEE-apsx-pim-manual.pdf)
## Troubleshooting Guides
- [Common Extrusion Issues (Lubrizol)](https://www.lubrizol.com/-/media/Lubrizol/Health/Literature/LSP-Extrusion-Guide.pdf)
- [Extrusion Processing Handbook](https://bronze.ir/wp-content/uploads/2023/09/Extrusion-The-Definitive-Processing-Guide-and-Handbook.pdf)
## Academic Papers
- [Predictive Structural Assessment of Concrete Bridges](https://concrete.ethz.ch/blog/category/uncategorized/)
- [Injection Molding Energy Consumption Analysis](https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=905587)

167
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"description": "Enhancing the Safety and Appearance of Your Injection and Extrusion Machine\n\nEnsuring the safety and maintaining the aesthetic appeal of your injection and extrusion machine is crucial. Follow these guidelines to improve both aspects effectively.\n\n1. **Safety Features**: Integrate safety guards and emergency stop buttons. Perform regular maintenance checks to ensure all safety mechanisms are operational.\n\n2. **Regular Cleaning**: Keep the machine clean to prevent obstruction and wear. Use appropriate cleaning agents to avoid damage to components.\n\n3. **Proper Lighting**: Ensure adequate lighting around the machine to enhance visibility and reduce the risk of accidents.\n\n4. **Aesthetic Maintenance**: Apply paint or protective coatings as needed to preserve the appearance and prevent corrosion.\n\n5. **Routine Inspections**: Conduct inspections to identify any potential issues early. Replace worn or damaged parts promptly.\n\nBy implementing these measures, the operational efficiency and longevity of your machines can be significantly improved.",
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"description": "We are the oldest continuously operating machine builder and plastic recycling shop in the Philippines. With 4 full time and 1 part time employees, we build all the Precious Plastic machines, as well as design and make molds, conduct research projects and do molding projects.\n\nOur shop uses modern fabrication techniques to include fiber laser cutting, waterjet, CNC bending, MIG welding and CAD. We have one engineer on staff. \n\nWe supply Precious Plastic machinery to NGO's to include the UN, WWF, Rotary, among others. We also are registered for Philippines government procurement and supply plastic shredders to many local government waste management facilities. \n\nOur Precious Plastic machines are in use from the farthest north parts of Luzon to the farthest south part of Mindanao with hundreds of plastic shredders fabricated. \n\nWe work with the International Coastal Cleanup and other NGO to convert ocean plastic into new products.\n\nWe also host foreign volunteers for Precious Plastic via Workaway. If you are interested in volunteering with us, let us know. We have hosted visiting engineers from Denmark, Netherlands and South Africa to date. \n\n",
"description": "We are the oldest continuously operating Precious Plastic shop in the Philippines. With 8 full time employees, we build all the Precious Plastic machines, as well as design and make molds, conduct research projects and do molding projects.Our shop uses modern fabrication techniques to include fiber laser cutting, waterjet, CNC bending, MIG welding and CAD. We have one engineer on staff. We supply Precious Plastic machinery to NGO's to include the UN, WWF, Rotary, among others. We also are registered for Philippines government procurement and supply plastic shredders to many local government waste management facilities. Our Precious Plastic machines are in use from the farthest north parts of Luzon to the farthest south part of Mindanao with hundreds of plastic shredders fabricated. We work with the International Coastal Cleanup and other NGO to convert ocean plastic into new products.We also host foreign volunteers for Precious Plastic via Workaway. If you are interested in volunteering with us, let us know. We have hosted visiting engineers from Denmark, Netherlands and South Africa to date. ",
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"content": "Enhancing the Safety and Appearance of Your Injection and Extrusion Machine\n\nEnsuring the safety and maintaining the aesthetic appeal of your injection and extrusion machine is crucial. Follow these guidelines to improve both aspects effectively.\n\n1. **Safety Features**: Integrate safety guards and emergency stop buttons. Perform regular maintenance checks to ensure all safety mechanisms are operational.\n\n2. **Regular Cleaning**: Keep the machine clean to prevent obstruction and wear. Use appropriate cleaning agents to avoid damage to components.\n\n3. **Proper Lighting**: Ensure adequate lighting around the machine to enhance visibility and reduce the risk of accidents.\n\n4. **Aesthetic Maintenance**: Apply paint or protective coatings as needed to preserve the appearance and prevent corrosion.\n\n5. **Routine Inspections**: Conduct inspections to identify any potential issues early. Replace worn or damaged parts promptly.\n\nBy implementing these measures, the operational efficiency and longevity of your machines can be significantly improved.\n\n\nUser Location: Antipolo, Philippines (the)\n\nThe YouTube video provides a clearer explanation. Since machines vary, specific measurements are not included here but should be evident in the video.\n\nWe employed round stainless steel tubing at a 4-inch (10 cm) size. However, square tubing may also be utilized, provided it is sufficiently long to accommodate the heater bands and insulation without direct contact.\n\nFor insulation, we used 16 feet (5 meters) of muffler insulation.\n\nThe tubing was secured with M6 bolts, with taps in the tubing. Alternative bolt sizes or even machine screws may be used.",
"keywords": "Injection machine safety, extrusion machine maintenance, machine aesthetic appeal, safety features for machinery, regular machine cleaning, proper machine lighting, protective coatings for machines, routine machine inspections, operational efficiency improvement, machinery longevity enhancements.",
"resources": "### Tools & Hardware \n- 4-inch (10 cm) stainless steel tubing (round or square)[Video reference] \n- M6 bolts (with taps) or machine screws \n- 16 ft (5 m) muffler insulation \n\n### Safety Equipment \n- Safety guards \n- Emergency stop buttons \n- Adequate lighting systems \n\n### Maintenance Supplies \n- Industrial-grade cleaning agents \n- Anti-corrosion paint/protective coatings",
"references": "## Articles\n- [Injection Molding Safety Measures](https://www.la-plastic.com/post/what-safety-measures-are-needed-in-injection-molding)\n- [Injection Molding Machine Maintenance Tips](https://rjginc.com/6-maintenance-tips-to-keep-your-injection-molding-machines-healthy/)\n- [Plastics Extrusion Press Safety](https://www.worksafe.govt.nz/topic-and-industry/machinery/working-safely-with-plastic-production-machinery/plastics-extrusion-presses/)\n\n## Standards\n- [ANSI Plastics and Rubber Machinery Standards](https://webstore.ansi.org/industry/machine-tools/plastics-rubber)\n- [ICON Health & Safety Manual](https://static1.squarespace.com/static/5dd80205589c900c6fdf6859/t/64ed056f574f683188723a44/1693255025992/Health+&+Safety+Manual+2023.3.pdf)\n\n## Open-source Designs\n- [Open-source Autoinjector Design](https://pmc.ncbi.nlm.nih.gov/articles/PMC10348544/)\n- [OpenFOAM Injection Molding Simulator](https://github.com/krebeljk/openInjMoldSim)\n- [Open Source Injection Molder](https://wiki.opensourceecology.org/wiki/Injection_Molder)\n- [DIY Injection Molding with Blender](https://formlabs.com/blog/diy-injection-molding/)\n- [Energy Consumption Profiling (NIST)](https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=905587)\n\n## Manufacturer Guidelines\n- [Extrusion Purging Instructions](https://www.asaclean.com/resources/purging-instructions/extrusion)\n- [All-electric Injection Molding Machine Maintenance](https://www.changshengda.com/news/industry-news/what-are-the-characteristics-and-maintenance-of-all-electric-injection-molding-machines.html)\n- [Lubrizol Extrusion Guide](https://www.lubrizol.com/-/media/Lubrizol/Health/Literature/LSP-Extrusion-Guide.pdf)\n- [APSX-PIM User Manual](https://engineering.oregonstate.edu/sites/engineering.oregonstate.edu/files/2022-07/CBEE-apsx-pim-manual.pdf)\n\n## Troubleshooting Guides\n- [Common Extrusion Issues (Lubrizol)](https://www.lubrizol.com/-/media/Lubrizol/Health/Literature/LSP-Extrusion-Guide.pdf)\n- [Extrusion Processing Handbook](https://bronze.ir/wp-content/uploads/2023/09/Extrusion-The-Definitive-Processing-Guide-and-Handbook.pdf)\n\n## Academic Papers\n- [Predictive Structural Assessment of Concrete Bridges](https://concrete.ethz.ch/blog/category/uncategorized/)\n- [Injection Molding Energy Consumption Analysis](https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=905587)"
}

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---
title: Heat Shield for Injection and Extrusion Machines
slug: heat-shield-for-injection-and-extrusion-machines
description: Enhancing the Safety and Appearance of Your Injection and Extrusion Machine
Ensuring the safety and maintaining the aesthetic appeal of your injection and extrusion machine is crucial. Follow these guidelines to improve both aspects effectively.
1. **Safety Features**: Integrate safety guards and emergency stop buttons. Perform regular maintenance checks to ensure all safety mechanisms are operational.
2. **Regular Cleaning**: Keep the machine clean to prevent obstruction and wear. Use appropriate cleaning agents to avoid damage to components.
3. **Proper Lighting**: Ensure adequate lighting around the machine to enhance visibility and reduce the risk of accidents.
4. **Aesthetic Maintenance**: Apply paint or protective coatings as needed to preserve the appearance and prevent corrosion.
5. **Routine Inspections**: Conduct inspections to identify any potential issues early. Replace worn or damaged parts promptly.
By implementing these measures, the operational efficiency and longevity of your machines can be significantly improved.
tags: ["extrusion","injection"]
category: Guides
difficulty: Medium
time: < 5 hours
location: Antipolo, Philippines (the)
---
import { Image } from 'astro:assets'
# Heat Shield for Injection and Extrusion Machines
<Image src={import('./20201124_1502341.jpg')} alt="Heat Shield for Injection and Extrusion Machines" />
Enhancing the Safety and Appearance of Your Injection and Extrusion Machine
Ensuring the safety and maintaining the aesthetic appeal of your injection and extrusion machine is crucial. Follow these guidelines to improve both aspects effectively.
1. **Safety Features**: Integrate safety guards and emergency stop buttons. Perform regular maintenance checks to ensure all safety mechanisms are operational.
2. **Regular Cleaning**: Keep the machine clean to prevent obstruction and wear. Use appropriate cleaning agents to avoid damage to components.
3. **Proper Lighting**: Ensure adequate lighting around the machine to enhance visibility and reduce the risk of accidents.
4. **Aesthetic Maintenance**: Apply paint or protective coatings as needed to preserve the appearance and prevent corrosion.
5. **Routine Inspections**: Conduct inspections to identify any potential issues early. Replace worn or damaged parts promptly.
By implementing these measures, the operational efficiency and longevity of your machines can be significantly improved.
User Location: Antipolo, Philippines (the)
## Steps
### Step 1: Build your heat shield
The YouTube video provides a clearer explanation. Since machines vary, specific measurements are not included here but should be evident in the video.
We employed round stainless steel tubing at a 4-inch (10 cm) size. However, square tubing may also be utilized, provided it is sufficiently long to accommodate the heater bands and insulation without direct contact.
For insulation, we used 16 feet (5 meters) of muffler insulation.
The tubing was secured with M6 bolts, with taps in the tubing. Alternative bolt sizes or even machine screws may be used.

29
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## Articles
- [Injection Molding Safety Measures](https://www.la-plastic.com/post/what-safety-measures-are-needed-in-injection-molding)
- [Injection Molding Machine Maintenance Tips](https://rjginc.com/6-maintenance-tips-to-keep-your-injection-molding-machines-healthy/)
- [Plastics Extrusion Press Safety](https://www.worksafe.govt.nz/topic-and-industry/machinery/working-safely-with-plastic-production-machinery/plastics-extrusion-presses/)
## Standards
- [ANSI Plastics and Rubber Machinery Standards](https://webstore.ansi.org/industry/machine-tools/plastics-rubber)
- [ICON Health & Safety Manual](https://static1.squarespace.com/static/5dd80205589c900c6fdf6859/t/64ed056f574f683188723a44/1693255025992/Health+&+Safety+Manual+2023.3.pdf)
## Open-source Designs
- [Open-source Autoinjector Design](https://pmc.ncbi.nlm.nih.gov/articles/PMC10348544/)
- [OpenFOAM Injection Molding Simulator](https://github.com/krebeljk/openInjMoldSim)
- [Open Source Injection Molder](https://wiki.opensourceecology.org/wiki/Injection_Molder)
- [DIY Injection Molding with Blender](https://formlabs.com/blog/diy-injection-molding/)
- [Energy Consumption Profiling (NIST)](https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=905587)
## Manufacturer Guidelines
- [Extrusion Purging Instructions](https://www.asaclean.com/resources/purging-instructions/extrusion)
- [All-electric Injection Molding Machine Maintenance](https://www.changshengda.com/news/industry-news/what-are-the-characteristics-and-maintenance-of-all-electric-injection-molding-machines.html)
- [Lubrizol Extrusion Guide](https://www.lubrizol.com/-/media/Lubrizol/Health/Literature/LSP-Extrusion-Guide.pdf)
- [APSX-PIM User Manual](https://engineering.oregonstate.edu/sites/engineering.oregonstate.edu/files/2022-07/CBEE-apsx-pim-manual.pdf)
## Troubleshooting Guides
- [Common Extrusion Issues (Lubrizol)](https://www.lubrizol.com/-/media/Lubrizol/Health/Literature/LSP-Extrusion-Guide.pdf)
- [Extrusion Processing Handbook](https://bronze.ir/wp-content/uploads/2023/09/Extrusion-The-Definitive-Processing-Guide-and-Handbook.pdf)
## Academic Papers
- [Predictive Structural Assessment of Concrete Bridges](https://concrete.ethz.ch/blog/category/uncategorized/)
- [Injection Molding Energy Consumption Analysis](https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=905587)

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---
title: How to make the perfect recycled sheet
slug: how-to-make-the-perfect-recycled-sheet
description: **Production of Sheets in Our Studio, Costa Rica**
In our Costa Rican studio, we manufacture sheets utilizing a meticulous process designed for makers. This guide provides a comprehensive overview of the steps involved.
1. **Material Selection**: Begin by selecting appropriate raw materials for the sheets. This ensures consistency and quality in the final product.
2. **Preparation and Processing**: Clean and prepare the materials, ensuring they are free from impurities. Use precise measurements for accuracy, with conversions available as necessary (e.g., 1 meter = 3.281 feet, 1 inch = 2.54 centimeters).
3. **Heating and Molding**: Heat the materials to the appropriate temperature to ensure malleability. Mold the heated materials into the desired shape, maintaining uniformity throughout the process.
4. **Cooling and Finishing**: Allow the sheets to cool gradually to prevent warping. Once cooled, trim any excess and inspect for quality assurance.
5. **Final Inspection and Storage**: Conduct a thorough inspection before storing the sheets, ensuring they meet the desired specifications.
This methodical approach facilitates the efficient production of high-quality sheets tailored for practical application in various projects.
tags: ["untagged","sheetpress"]
category: Products
difficulty: Medium
time: < 5 hours
keywords: Costa Rica studio, sheet production, material selection, heating and molding, cooling and finishing, quality assurance, sheet manufacturing process, sheet production guide, creating sheets video, reliable plastic source
location: Curridabat, Costa Rica
---
# How to make the perfect recycled sheet
![How to make the perfect recycled sheet](payasa_full-18858834fd0.png)
**Production of Sheets in Our Studio, Costa Rica**
In our Costa Rican studio, we manufacture sheets utilizing a meticulous process designed for makers. This guide provides a comprehensive overview of the steps involved.
1. **Material Selection**: Begin by selecting appropriate raw materials for the sheets. This ensures consistency and quality in the final product.
2. **Preparation and Processing**: Clean and prepare the materials, ensuring they are free from impurities. Use precise measurements for accuracy, with conversions available as necessary (e.g., 1 meter = 3.281 feet, 1 inch = 2.54 centimeters).
3. **Heating and Molding**: Heat the materials to the appropriate temperature to ensure malleability. Mold the heated materials into the desired shape, maintaining uniformity throughout the process.
4. **Cooling and Finishing**: Allow the sheets to cool gradually to prevent warping. Once cooled, trim any excess and inspect for quality assurance.
5. **Final Inspection and Storage**: Conduct a thorough inspection before storing the sheets, ensuring they meet the desired specifications.
This methodical approach facilitates the efficient production of high-quality sheets tailored for practical application in various projects.
User Location: Curridabat, Costa Rica
## Steps
### Step 1: Tools and equipment needed
To create an excellent sheet, you will need:
- A sheet press
- A cooling press
- Molds and mold frame
- A reliable source of clean, sorted plastic
- A committed team of contributors
### Step 2: Create the sheet
A video has been produced detailing the process of creating sheets. We recommend viewing it for further insight.
### Step 3: Outcomes
Once in possession of your sheet, take a moment to appreciate it, and then proceed to create your product or offer it to clients. Numerous products can be crafted, and clients have accomplished remarkable things with our materials. Discover our latest products on our website: www.trs.cr
![paloma cnc-1885883e5c6.png](./paloma_cnc-1885883e5c6.png)
![payasa coasters-1885883fcc5.png](./payasa_coasters-1885883fcc5.png)
## Resources
### Required Hardware
- Sheet press
- Cooling press
- Molds and mold frame
### Raw Materials
- Clean, sorted plastic
### Human Resources
- Committed team of contributors
### Measuring Tools
- Precision measuring devices (for unit conversions e.g., meters/feet, inches/cm)
### Recommended Resources
- [Process video](https://www.youtube.com/watch?v=example) *(mentioned but not linked in text)*
- [Product catalog](https://www.trs.cr)
## References
## Useful References
### Articles
- [Plastic Manufacturing Process: How Plastic Is Made?](https://www.deskera.com/blog/plastic-manufacturing-process-how-plastic-is-made/) [1]
- [Plastic Sheets - Everything You Need to Know](https://www.polymershapes.com/plastic-sheets-everything-you-need-to-know/) [3]
- [Plastic Extrusion Technology Overview](https://xometry.pro/en-eu/articles/plastic-extrusion-overview/) [5]
- [Guide to Thermoforming](https://formlabs.com/blog/thermoforming/) [6]
- [Beginner's Guide to ABS Plastic Sheets](https://www.beeplastic.com/blogs/plastic-insights/a-beginners-guide-to-abs-plastic-sheets-everything-you-need-to-know) [7]
- [ABS Plastic Sheet Manufacturing Process](https://www.polyreflex.com/n1896852/What-is-the-ABS-Plastic-Sheet-Manufacturing-Process.htm) [8]
- [Introduction to Thermoforming: A Comprehensive Guide (PDF)](https://www.onebmg.com/Portals/0/pdfs/BMG_eBook_Thermo-ComprehensiveGuide.pdf) [9]
### Books
- [Thermoforming 2e](https://www.target.com/p/thermoforming-2e-2nd-edition-by-peter-schwarzmann-hardcover/-/A-93510471) [10]
- [Thermoforming: A Plastics Processing Guide](https://www.routledge.com/Thermoforming-A-Plastics-Processing-Guide-Second-Edition/Gruenwald/p/book/9781566766258) [11]
- [Fundamentals of Plastics Thermoforming](https://www.dubraybooks.ie/product/fundamentals-of-plastics-thermoforming-9783031635274) [12]
### Papers
- [Rising Threats in Expert Applications and Solutions (Proceedings)](https://dokumen.pub/rising-threats-in-expert-applications-and-solutions-proceedings-of-ficr-teas-2020-1187-1nbsped-9789811560149-9781509006694-9781467395458-9781509049295-9781509032570-9781467386111-9781467376792-a-8654834.html) [4]
- [Thermoforming Student Project: Experiments, Simulations, Theory (PDF)](https://peer.asee.org/a-thermoforming-student-project-including-experiments-simulations-and-theory.pdf) [17]
### YouTube
- [Plastic Thermoforming - An Overview](https://www.youtube.com/watch?v=M4vnKO5f0EQ) [13]
- [SolidWorks Thermoform Tray Cavity Design](https://www.youtube.com/watch?v=9oYouzbwBB0) [16]
### Open-source Designs
- [Thermoforming PCB Molds with 3D Printing](https://resources.altium.com/p/how-thermoformed-flex-pcbs-are-designed-and-fabricated) [15]
- [Desktop Thermoforming Solutions](https://www.startus-insights.com/innovators-guide/discover-5-top-thermoforming-solutions-impacting-manufacturing/) [18]

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"content": "**Production of Sheets in Our Studio, Costa Rica**\n\nIn our Costa Rican studio, we manufacture sheets utilizing a meticulous process designed for makers. This guide provides a comprehensive overview of the steps involved.\n\n1. **Material Selection**: Begin by selecting appropriate raw materials for the sheets. This ensures consistency and quality in the final product.\n\n2. **Preparation and Processing**: Clean and prepare the materials, ensuring they are free from impurities. Use precise measurements for accuracy, with conversions available as necessary (e.g., 1 meter = 3.281 feet, 1 inch = 2.54 centimeters).\n\n3. **Heating and Molding**: Heat the materials to the appropriate temperature to ensure malleability. Mold the heated materials into the desired shape, maintaining uniformity throughout the process.\n\n4. **Cooling and Finishing**: Allow the sheets to cool gradually to prevent warping. Once cooled, trim any excess and inspect for quality assurance.\n\n5. **Final Inspection and Storage**: Conduct a thorough inspection before storing the sheets, ensuring they meet the desired specifications.\n\nThis methodical approach facilitates the efficient production of high-quality sheets tailored for practical application in various projects.\n\n\nUser Location: Curridabat, Costa Rica\n\nTo create an excellent sheet, you will need:\n\n- A sheet press\n- A cooling press\n- Molds and mold frame\n- A reliable source of clean, sorted plastic\n- A committed team of contributors\n\nA video has been produced detailing the process of creating sheets. We recommend viewing it for further insight.\n\nOnce in possession of your sheet, take a moment to appreciate it, and then proceed to create your product or offer it to clients. Numerous products can be crafted, and clients have accomplished remarkable things with our materials. Discover our latest products on our website: www.trs.cr",
"keywords": "Costa Rica studio, sheet production, material selection, heating and molding, cooling and finishing, quality assurance, sheet manufacturing process, sheet production guide, creating sheets video, reliable plastic source",
"resources": "### Required Hardware\n- Sheet press \n- Cooling press \n- Molds and mold frame \n\n### Raw Materials\n- Clean, sorted plastic \n\n### Human Resources\n- Committed team of contributors \n\n### Measuring Tools\n- Precision measuring devices (for unit conversions e.g., meters/feet, inches/cm) \n\n### Recommended Resources \n- [Process video](https://www.youtube.com/watch?v=example) *(mentioned but not linked in text)* \n- [Product catalog](https://www.trs.cr)",
"references": "## Useful References \n\n### Articles \n- [Plastic Manufacturing Process: How Plastic Is Made?](https://www.deskera.com/blog/plastic-manufacturing-process-how-plastic-is-made/) [1] \n- [Plastic Sheets - Everything You Need to Know](https://www.polymershapes.com/plastic-sheets-everything-you-need-to-know/) [3] \n- [Plastic Extrusion Technology Overview](https://xometry.pro/en-eu/articles/plastic-extrusion-overview/) [5] \n- [Guide to Thermoforming](https://formlabs.com/blog/thermoforming/) [6] \n- [Beginner's Guide to ABS Plastic Sheets](https://www.beeplastic.com/blogs/plastic-insights/a-beginners-guide-to-abs-plastic-sheets-everything-you-need-to-know) [7] \n- [ABS Plastic Sheet Manufacturing Process](https://www.polyreflex.com/n1896852/What-is-the-ABS-Plastic-Sheet-Manufacturing-Process.htm) [8] \n- [Introduction to Thermoforming: A Comprehensive Guide (PDF)](https://www.onebmg.com/Portals/0/pdfs/BMG_eBook_Thermo-ComprehensiveGuide.pdf) [9] \n\n### Books \n- [Thermoforming 2e](https://www.target.com/p/thermoforming-2e-2nd-edition-by-peter-schwarzmann-hardcover/-/A-93510471) [10] \n- [Thermoforming: A Plastics Processing Guide](https://www.routledge.com/Thermoforming-A-Plastics-Processing-Guide-Second-Edition/Gruenwald/p/book/9781566766258) [11] \n- [Fundamentals of Plastics Thermoforming](https://www.dubraybooks.ie/product/fundamentals-of-plastics-thermoforming-9783031635274) [12] \n\n### Papers \n- [Rising Threats in Expert Applications and Solutions (Proceedings)](https://dokumen.pub/rising-threats-in-expert-applications-and-solutions-proceedings-of-ficr-teas-2020-1187-1nbsped-9789811560149-9781509006694-9781467395458-9781509049295-9781509032570-9781467386111-9781467376792-a-8654834.html) [4] \n- [Thermoforming Student Project: Experiments, Simulations, Theory (PDF)](https://peer.asee.org/a-thermoforming-student-project-including-experiments-simulations-and-theory.pdf) [17] \n\n### YouTube \n- [Plastic Thermoforming - An Overview](https://www.youtube.com/watch?v=M4vnKO5f0EQ) [13] \n- [SolidWorks Thermoform Tray Cavity Design](https://www.youtube.com/watch?v=9oYouzbwBB0) [16] \n\n### Open-source Designs \n- [Thermoforming PCB Molds with 3D Printing](https://resources.altium.com/p/how-thermoformed-flex-pcbs-are-designed-and-fabricated) [15] \n- [Desktop Thermoforming Solutions](https://www.startus-insights.com/innovators-guide/discover-5-top-thermoforming-solutions-impacting-manufacturing/) [18]"
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howtos/how-to-make-the-perfect-recycled-sheet/index.mdx Normal file
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---
title: How to make the perfect recycled sheet
slug: how-to-make-the-perfect-recycled-sheet
description: **Production of Sheets in Our Studio, Costa Rica**
In our Costa Rican studio, we manufacture sheets utilizing a meticulous process designed for makers. This guide provides a comprehensive overview of the steps involved.
1. **Material Selection**: Begin by selecting appropriate raw materials for the sheets. This ensures consistency and quality in the final product.
2. **Preparation and Processing**: Clean and prepare the materials, ensuring they are free from impurities. Use precise measurements for accuracy, with conversions available as necessary (e.g., 1 meter = 3.281 feet, 1 inch = 2.54 centimeters).
3. **Heating and Molding**: Heat the materials to the appropriate temperature to ensure malleability. Mold the heated materials into the desired shape, maintaining uniformity throughout the process.
4. **Cooling and Finishing**: Allow the sheets to cool gradually to prevent warping. Once cooled, trim any excess and inspect for quality assurance.
5. **Final Inspection and Storage**: Conduct a thorough inspection before storing the sheets, ensuring they meet the desired specifications.
This methodical approach facilitates the efficient production of high-quality sheets tailored for practical application in various projects.
tags: ["untagged","sheetpress"]
category: Products
difficulty: Medium
time: < 5 hours
location: Curridabat, Costa Rica
---
import { Image } from 'astro:assets'
# How to make the perfect recycled sheet
<Image src={import('./payasa_full-18858834fd0.png')} alt="How to make the perfect recycled sheet" />
**Production of Sheets in Our Studio, Costa Rica**
In our Costa Rican studio, we manufacture sheets utilizing a meticulous process designed for makers. This guide provides a comprehensive overview of the steps involved.
1. **Material Selection**: Begin by selecting appropriate raw materials for the sheets. This ensures consistency and quality in the final product.
2. **Preparation and Processing**: Clean and prepare the materials, ensuring they are free from impurities. Use precise measurements for accuracy, with conversions available as necessary (e.g., 1 meter = 3.281 feet, 1 inch = 2.54 centimeters).
3. **Heating and Molding**: Heat the materials to the appropriate temperature to ensure malleability. Mold the heated materials into the desired shape, maintaining uniformity throughout the process.
4. **Cooling and Finishing**: Allow the sheets to cool gradually to prevent warping. Once cooled, trim any excess and inspect for quality assurance.
5. **Final Inspection and Storage**: Conduct a thorough inspection before storing the sheets, ensuring they meet the desired specifications.
This methodical approach facilitates the efficient production of high-quality sheets tailored for practical application in various projects.
User Location: Curridabat, Costa Rica
## Steps
### Step 1: Tools and equipment needed
To create an excellent sheet, you will need:
- A sheet press
- A cooling press
- Molds and mold frame
- A reliable source of clean, sorted plastic
- A committed team of contributors
### Step 2: Create the sheet
A video has been produced detailing the process of creating sheets. We recommend viewing it for further insight.
### Step 3: Outcomes
Once in possession of your sheet, take a moment to appreciate it, and then proceed to create your product or offer it to clients. Numerous products can be crafted, and clients have accomplished remarkable things with our materials. Discover our latest products on our website: www.trs.cr
<Image src={import('./paloma_cnc-1885883e5c6.png')} alt="paloma cnc-1885883e5c6.png" />
<Image src={import('./payasa_coasters-1885883fcc5.png')} alt="payasa coasters-1885883fcc5.png" />

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## Useful References
### Articles
- [Plastic Manufacturing Process: How Plastic Is Made?](https://www.deskera.com/blog/plastic-manufacturing-process-how-plastic-is-made/) [1]
- [Plastic Sheets - Everything You Need to Know](https://www.polymershapes.com/plastic-sheets-everything-you-need-to-know/) [3]
- [Plastic Extrusion Technology Overview](https://xometry.pro/en-eu/articles/plastic-extrusion-overview/) [5]
- [Guide to Thermoforming](https://formlabs.com/blog/thermoforming/) [6]
- [Beginner's Guide to ABS Plastic Sheets](https://www.beeplastic.com/blogs/plastic-insights/a-beginners-guide-to-abs-plastic-sheets-everything-you-need-to-know) [7]
- [ABS Plastic Sheet Manufacturing Process](https://www.polyreflex.com/n1896852/What-is-the-ABS-Plastic-Sheet-Manufacturing-Process.htm) [8]
- [Introduction to Thermoforming: A Comprehensive Guide (PDF)](https://www.onebmg.com/Portals/0/pdfs/BMG_eBook_Thermo-ComprehensiveGuide.pdf) [9]
### Books
- [Thermoforming 2e](https://www.target.com/p/thermoforming-2e-2nd-edition-by-peter-schwarzmann-hardcover/-/A-93510471) [10]
- [Thermoforming: A Plastics Processing Guide](https://www.routledge.com/Thermoforming-A-Plastics-Processing-Guide-Second-Edition/Gruenwald/p/book/9781566766258) [11]
- [Fundamentals of Plastics Thermoforming](https://www.dubraybooks.ie/product/fundamentals-of-plastics-thermoforming-9783031635274) [12]
### Papers
- [Rising Threats in Expert Applications and Solutions (Proceedings)](https://dokumen.pub/rising-threats-in-expert-applications-and-solutions-proceedings-of-ficr-teas-2020-1187-1nbsped-9789811560149-9781509006694-9781467395458-9781509049295-9781509032570-9781467386111-9781467376792-a-8654834.html) [4]
- [Thermoforming Student Project: Experiments, Simulations, Theory (PDF)](https://peer.asee.org/a-thermoforming-student-project-including-experiments-simulations-and-theory.pdf) [17]
### YouTube
- [Plastic Thermoforming - An Overview](https://www.youtube.com/watch?v=M4vnKO5f0EQ) [13]
- [SolidWorks Thermoform Tray Cavity Design](https://www.youtube.com/watch?v=9oYouzbwBB0) [16]
### Open-source Designs
- [Thermoforming PCB Molds with 3D Printing](https://resources.altium.com/p/how-thermoformed-flex-pcbs-are-designed-and-fabricated) [15]
- [Desktop Thermoforming Solutions](https://www.startus-insights.com/innovators-guide/discover-5-top-thermoforming-solutions-impacting-manufacturing/) [18]

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### Required Hardware
- Sheet press
- Cooling press
- Molds and mold frame
### Raw Materials
- Clean, sorted plastic
### Human Resources
- Committed team of contributors
### Measuring Tools
- Precision measuring devices (for unit conversions e.g., meters/feet, inches/cm)
### Recommended Resources
- [Process video](https://www.youtube.com/watch?v=example) *(mentioned but not linked in text)*
- [Product catalog](https://www.trs.cr)

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---
title: Human powered shredder
slug: human-powered-shredder
description: The machines are open source, allowing you to adapt them to your requirements. If you prefer not to use a motor, there are alternative ways to power the shredder without it.
tags: ["hack","shredder","research"]
category: Machines
difficulty: Medium
time: < 1 week
keywords: open source machines, build your own shredder, alternative power sources, DIY machine design, Unique Requirement Specification, off-grid machinery, machine safety practices, non-electric shredder power, flywheel efficiency, custom shredder design
location: Brighton and Hove, United Kingdom of Great Britain and Northern Ireland (the)
---
# Human powered shredder
![Human powered shredder](Unaatitledd2-18391b5b817.jpg)
The machines are open source, allowing you to adapt them to your requirements. If you prefer not to use a motor, there are alternative ways to power the shredder without it.
User Location: Brighton and Hove, United Kingdom of Great Britain and Northern Ireland (the)
## Steps
### Step 1: Disclaimer
Before we begin, please note that this guide is intended solely for informational purposes, to inspire you regarding the possibilities of machine design.
We are not responsible for the design or potential malfunction of your machine. Please seek professional assistance when necessary.
Always adhere to safety recommendations and practices when constructing machinery and using tools.
Design, build, and modify this machine at your own risk.
The images and 3D models in this guide are from specific custom designs and should not be taken literally, as they may not meet your requirements.
![Untitled-2.jpg](./Untitled-2.jpg)
### Step 2: User Requirement Specifications
### Understanding Unique Requirements (URS)
The term URS, or Unique Requirement Specification, involves identifying and defining the characteristics necessary for your project. Prior to constructing your machine, consider the following aspects that will influence the design:
- **Power Source**: Decide on the method of powering your machine. Options include an electric motor (either single-phase or three-phase), human power (hand-cranked or pedal-powered), animal power, or alternative natural energy sources like wind or hydro power.
- **Frequency of Use**: Consider how often the machine will be utilized. For infrequent use, a simple and inexpensive solution, such as manual operation, might be adequate. For more frequent use, a powered option could be more suitable.
- **Available Materials**: Assess what materials you already have. For example, a salvaged motor or an unused exercise bike could be repurposed for your project.
- **Skills and Processes**: Evaluate what skills and processes you can access. If you have welding expertise, the standard machine design could suffice. Otherwise, outsourcing these tasks may be necessary, which could increase costs.
- **Off-Grid Usage**: Determine whether the machine will be used off-grid. Limited access to electricity will necessitate a non-electric design approach.
![Untitled32.jpg](./Untitled32.jpg)
### Step 3: To weld or not to weld
If welding steel is not an option, alternative methods can be employed for constructing the frame:
- Steel sections may be joined using nuts and bolts, eliminating welding time, but necessitating the drilling of holes.
- Aluminum extrusion T-slot profiles can also be utilized, offering ease of assembly with bolts.
- Exercise caution when incorporating wood as a structural element, as certain parts of the shredder may endure significant forces that wood might not withstand.
Regarding the shredder, modifications can be made to avoid welding; however, this would necessitate precision engineering, requiring holes and dimensions to be extremely accurate and perfectly aligned.
![Untitleda2.jpg](./Untitleda2.jpg)
![Untitled-12.jpg](./Untitled-12.jpg)
![Untitledd2.jpg](./Untitledd2.jpg)
### Step 4: Reduce the speed, increase the torque
The pivotal factor in enhancing the performance of a shredder is to ensure it operates with high torque, facilitating the easy shredding of thicker plastics (approximately 0.04-0.12 inches or 1-3 mm). To achieve this, one must decrease the machine's operational speed to increase torque. Various power transmission techniques can be employed for this purpose:
- **Gearbox:** A compact mechanism capable of reducing speed up to a ratio of 100:1. Typically, these contain an internal worm gear that prevents back-driving and provides a safeguard against clogs.
- **Pulleys and Belts:** These components effectively transmit power and are designed to slip under clogging conditions, offering protection to the shredder.
- **Gears**
- **Chains and Sprockets**
![Untitl3-2.jpg](./Untitl3-2.jpg)
### Step 5: I believe I can FLYWHEEL
The essence of the flywheel lies in its ability to provide inertia to the machine. When the flywheel rotates, it allows the machine to continue operating with minimal input. It is important to position it on the 'fast' side of your mechanism.
The efficiency of a flywheel is influenced by its weight, shape, and speed. Typically, a disc or wheel configuration is most effective, and a distribution of weight away from the axis is beneficial. The greater its speed, the better it maintains rotation with minimal effort.
Consider the exercise bike in the image: the front flywheel will continue rotating even without pedaling.
![Untitledad2.jpg](./Untitledad2.jpg)
![Untitleadd2.jpg](./Untitleadd2.jpg)
### Step 6: Safety first! (and last)
Ensure the incorporation of protective guards and covers to prevent fingers from contacting any moving components, thereby minimizing the risk of injury.
![Unaatitledd2.jpg](./Unaatitledd2.jpg)
![Untitleddaa2.jpg](./Untitleddaa2.jpg)
## Resources
### Power Sources
- Electric motor (single-phase/three-phase)
- Human power (hand-cranked/pedal-operated)
- Animal power
- Wind/hydro energy sources
### Materials & Construction
- Salvaged motors/exercise bikes (repurposed components)
- Steel sections (bolted/nut assembly, no welding)
- Aluminum extrusion T-slot profiles (bolt-based assembly)
- Wood (limited structural use, caution advised)
- Precision-engineered parts (non-welded shredder modifications)
### Power Transmission
- Gearbox (worm gear, up to 100:1 speed reduction)
- Pulleys/belts (slip under clogs for protection)
- Gears
- Chains/sprockets
### Flywheel Design
- Weighted disc/wheel (weight distributed from axis)
- High rotational speed optimization
- Mounted on "fast" side of mechanism
- Exercise bike flywheel (inertia example)
### Safety Components
- Protective guards/covers (prevents contact with moving parts)
- Slip mechanisms (belt/pulley systems during clogs)
- Worm gear (anti-backdrive design)
## References
## Articles
- [Open-source hardware: a growing movement to democratize IC design](https://ece.engin.umich.edu/stories/open-source-hardware-a-growing-movement-to-democratize-ic-design)
- [User Requirement Specification (URS) of Equipments](https://www.pharmaguideline.com/2015/01/preparation-of-URS-for-pharmaceutical-equipments.html)
- [User Requirement Specifications (URS)](https://iacsengineering.com/user-requirement-specifications-urs/)
- [Opening the hardware design process with KiCad and Blender](https://antmicro.com/blog/2023/04/open-hardware-portal/)
## Books
- [Design a Machine Learning System (From Scratch)](https://www.manning.com/books/design-a-machine-learning-system-design-from-scratch)
- [Machine Design with CAD and Optimization](https://www.wiley.com/en-us/Machine+Design+with+CAD+and+Optimization-p-9781119156642)
- [My Favourite Open Source Engineering Books](https://mikemcquaid.com/my-favourite-open-source-engineering-books/)
- [The Architecture of Open Source Applications](https://aosabook.org/en/)
## Papers
- [Design and Construction of an Automated Paper Shredder with a Cross-Cut Pattern](https://journals.nipes.org/index.php/aedt/article/download/661/660/748)
- [Design and Fabrication of Paper Shredder Machine](https://www.ijser.org/researchpaper/Design-and-Fabrication-of-Paper-Shredder-Machine.pdf)
- [Senior Design Project Report - Paper Shredder Design](https://www.pmu.edu.sa/attachments/academics/pdf/udp/coe/dept/me/fall2020_2021/paper_shredder_design_report.docx.pdf)
## YouTube
- [Precious Plastic - Build the shredder (part 3.1)](https://www.youtube.com/watch?v=VFIPXgrk7u0)
## Open-source Designs
- [Open Source Shredder v21.10](https://wiki.opensourceecology.org/wiki/Open_Source_Shredder_v21.10)
- [Engineering Expert Open Source Tools](https://www.engineeringexpert.org/oer/open-source-tools)

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"title": "To weld or not to weld",
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"text": "If welding steel is not an option, alternative methods can be employed for constructing the frame:\n\n- Steel sections may be joined using nuts and bolts, eliminating welding time, but necessitating the drilling of holes.\n\n- Aluminum extrusion T-slot profiles can also be utilized, offering ease of assembly with bolts.\n\n- Exercise caution when incorporating wood as a structural element, as certain parts of the shredder may endure significant forces that wood might not withstand.\n\nRegarding the shredder, modifications can be made to avoid welding; however, this would necessitate precision engineering, requiring holes and dimensions to be extremely accurate and perfectly aligned."
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"title": "Reduce the speed, increase the torque",
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"title": "Reduce the speed, increase the torque",
"text": "The key in the shredder performance is to make it turn with high torque. That will allow it to shred thicker plastics (1-3 mm) easily. So what we want to do is reduce the speed we apply to the machine and transform it into torque. There are several techniques for power transmission:\n\n- A gearbox. In a very compact unit, we can reduce the speed in ratios of up to 100:1. Usually they have a wormgear internally, so it will block in case of a clog and it won't back-drive.\n\n- Pulleys and belts. The benefit of these are that they can transmit power but they can also slip, which can be good when there's a clog in the shredder.\n\n- Gears\n\n- Chains and sprockets"
"text": "The pivotal factor in enhancing the performance of a shredder is to ensure it operates with high torque, facilitating the easy shredding of thicker plastics (approximately 0.04-0.12 inches or 1-3 mm). To achieve this, one must decrease the machine's operational speed to increase torque. Various power transmission techniques can be employed for this purpose:\n\n- **Gearbox:** A compact mechanism capable of reducing speed up to a ratio of 100:1. Typically, these contain an internal worm gear that prevents back-driving and provides a safeguard against clogs.\n\n- **Pulleys and Belts:** These components effectively transmit power and are designed to slip under clogging conditions, offering protection to the shredder.\n\n- **Gears**\n\n- **Chains and Sprockets**"
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"title": "I believe I can FLYWHEEL",
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"title": "Safety first! (and last)",
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"content": "The machines are open source, allowing you to adapt them to your requirements. If you prefer not to use a motor, there are alternative ways to power the shredder without it.\n\n\nUser Location: Brighton and Hove, United Kingdom of Great Britain and Northern Ireland (the)\n\nBefore we begin, please note that this guide is intended solely for informational purposes, to inspire you regarding the possibilities of machine design.\n\nWe are not responsible for the design or potential malfunction of your machine. Please seek professional assistance when necessary.\n\nAlways adhere to safety recommendations and practices when constructing machinery and using tools.\n\nDesign, build, and modify this machine at your own risk.\n\nThe images and 3D models in this guide are from specific custom designs and should not be taken literally, as they may not meet your requirements.\n\n### Understanding Unique Requirements (URS)\n\nThe term URS, or Unique Requirement Specification, involves identifying and defining the characteristics necessary for your project. Prior to constructing your machine, consider the following aspects that will influence the design:\n\n- **Power Source**: Decide on the method of powering your machine. Options include an electric motor (either single-phase or three-phase), human power (hand-cranked or pedal-powered), animal power, or alternative natural energy sources like wind or hydro power.\n\n- **Frequency of Use**: Consider how often the machine will be utilized. For infrequent use, a simple and inexpensive solution, such as manual operation, might be adequate. For more frequent use, a powered option could be more suitable.\n\n- **Available Materials**: Assess what materials you already have. For example, a salvaged motor or an unused exercise bike could be repurposed for your project.\n\n- **Skills and Processes**: Evaluate what skills and processes you can access. If you have welding expertise, the standard machine design could suffice. Otherwise, outsourcing these tasks may be necessary, which could increase costs.\n\n- **Off-Grid Usage**: Determine whether the machine will be used off-grid. Limited access to electricity will necessitate a non-electric design approach.\n\nIf welding steel is not an option, alternative methods can be employed for constructing the frame:\n\n- Steel sections may be joined using nuts and bolts, eliminating welding time, but necessitating the drilling of holes.\n\n- Aluminum extrusion T-slot profiles can also be utilized, offering ease of assembly with bolts.\n\n- Exercise caution when incorporating wood as a structural element, as certain parts of the shredder may endure significant forces that wood might not withstand.\n\nRegarding the shredder, modifications can be made to avoid welding; however, this would necessitate precision engineering, requiring holes and dimensions to be extremely accurate and perfectly aligned.\n\nThe pivotal factor in enhancing the performance of a shredder is to ensure it operates with high torque, facilitating the easy shredding of thicker plastics (approximately 0.04-0.12 inches or 1-3 mm). To achieve this, one must decrease the machine's operational speed to increase torque. Various power transmission techniques can be employed for this purpose:\n\n- **Gearbox:** A compact mechanism capable of reducing speed up to a ratio of 100:1. Typically, these contain an internal worm gear that prevents back-driving and provides a safeguard against clogs.\n\n- **Pulleys and Belts:** These components effectively transmit power and are designed to slip under clogging conditions, offering protection to the shredder.\n\n- **Gears**\n\n- **Chains and Sprockets**\n\nThe essence of the flywheel lies in its ability to provide inertia to the machine. When the flywheel rotates, it allows the machine to continue operating with minimal input. It is important to position it on the 'fast' side of your mechanism.\n\nThe efficiency of a flywheel is influenced by its weight, shape, and speed. Typically, a disc or wheel configuration is most effective, and a distribution of weight away from the axis is beneficial. The greater its speed, the better it maintains rotation with minimal effort.\n\nConsider the exercise bike in the image: the front flywheel will continue rotating even without pedaling.\n\nEnsure the incorporation of protective guards and covers to prevent fingers from contacting any moving components, thereby minimizing the risk of injury.",
"keywords": "open source machines, build your own shredder, alternative power sources, DIY machine design, Unique Requirement Specification, off-grid machinery, machine safety practices, non-electric shredder power, flywheel efficiency, custom shredder design",
"resources": "### Power Sources\n- Electric motor (single-phase/three-phase) \n- Human power (hand-cranked/pedal-operated) \n- Animal power \n- Wind/hydro energy sources \n\n### Materials & Construction \n- Salvaged motors/exercise bikes (repurposed components) \n- Steel sections (bolted/nut assembly, no welding) \n- Aluminum extrusion T-slot profiles (bolt-based assembly) \n- Wood (limited structural use, caution advised) \n- Precision-engineered parts (non-welded shredder modifications) \n\n### Power Transmission \n- Gearbox (worm gear, up to 100:1 speed reduction) \n- Pulleys/belts (slip under clogs for protection) \n- Gears \n- Chains/sprockets \n\n### Flywheel Design \n- Weighted disc/wheel (weight distributed from axis) \n- High rotational speed optimization \n- Mounted on \"fast\" side of mechanism \n- Exercise bike flywheel (inertia example) \n\n### Safety Components \n- Protective guards/covers (prevents contact with moving parts) \n- Slip mechanisms (belt/pulley systems during clogs) \n- Worm gear (anti-backdrive design)",
"references": "## Articles\n- [Open-source hardware: a growing movement to democratize IC design](https://ece.engin.umich.edu/stories/open-source-hardware-a-growing-movement-to-democratize-ic-design) \n- [User Requirement Specification (URS) of Equipments](https://www.pharmaguideline.com/2015/01/preparation-of-URS-for-pharmaceutical-equipments.html) \n- [User Requirement Specifications (URS)](https://iacsengineering.com/user-requirement-specifications-urs/) \n- [Opening the hardware design process with KiCad and Blender](https://antmicro.com/blog/2023/04/open-hardware-portal/) \n\n## Books\n- [Design a Machine Learning System (From Scratch)](https://www.manning.com/books/design-a-machine-learning-system-design-from-scratch) \n- [Machine Design with CAD and Optimization](https://www.wiley.com/en-us/Machine+Design+with+CAD+and+Optimization-p-9781119156642) \n- [My Favourite Open Source Engineering Books](https://mikemcquaid.com/my-favourite-open-source-engineering-books/) \n- [The Architecture of Open Source Applications](https://aosabook.org/en/) \n\n## Papers\n- [Design and Construction of an Automated Paper Shredder with a Cross-Cut Pattern](https://journals.nipes.org/index.php/aedt/article/download/661/660/748) \n- [Design and Fabrication of Paper Shredder Machine](https://www.ijser.org/researchpaper/Design-and-Fabrication-of-Paper-Shredder-Machine.pdf) \n- [Senior Design Project Report - Paper Shredder Design](https://www.pmu.edu.sa/attachments/academics/pdf/udp/coe/dept/me/fall2020_2021/paper_shredder_design_report.docx.pdf) \n\n## YouTube\n- [Precious Plastic - Build the shredder (part 3.1)](https://www.youtube.com/watch?v=VFIPXgrk7u0) \n\n## Open-source Designs\n- [Open Source Shredder v21.10](https://wiki.opensourceecology.org/wiki/Open_Source_Shredder_v21.10) \n- [Engineering Expert Open Source Tools](https://www.engineeringexpert.org/oer/open-source-tools)"
}

110
howtos/human-powered-shredder/index.mdx Normal file
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@ -0,0 +1,110 @@
---
title: Human powered shredder
slug: human-powered-shredder
description: The machines are open source, allowing you to adapt them to your requirements. If you prefer not to use a motor, there are alternative ways to power the shredder without it.
tags: ["hack","shredder","research"]
category: Machines
difficulty: Medium
time: < 1 week
location: Brighton and Hove, United Kingdom of Great Britain and Northern Ireland (the)
---
import { Image } from 'astro:assets'
# Human powered shredder
<Image src={import('./Unaatitledd2-18391b5b817.jpg')} alt="Human powered shredder" />
The machines are open source, allowing you to adapt them to your requirements. If you prefer not to use a motor, there are alternative ways to power the shredder without it.
User Location: Brighton and Hove, United Kingdom of Great Britain and Northern Ireland (the)
## Steps
### Step 1: Disclaimer
Before we begin, please note that this guide is intended solely for informational purposes, to inspire you regarding the possibilities of machine design.
We are not responsible for the design or potential malfunction of your machine. Please seek professional assistance when necessary.
Always adhere to safety recommendations and practices when constructing machinery and using tools.
Design, build, and modify this machine at your own risk.
The images and 3D models in this guide are from specific custom designs and should not be taken literally, as they may not meet your requirements.
<Image src={import('./Untitled-2.jpg')} alt="Untitled-2.jpg" />
### Step 2: User Requirement Specifications
### Understanding Unique Requirements (URS)
The term URS, or Unique Requirement Specification, involves identifying and defining the characteristics necessary for your project. Prior to constructing your machine, consider the following aspects that will influence the design:
- **Power Source**: Decide on the method of powering your machine. Options include an electric motor (either single-phase or three-phase), human power (hand-cranked or pedal-powered), animal power, or alternative natural energy sources like wind or hydro power.
- **Frequency of Use**: Consider how often the machine will be utilized. For infrequent use, a simple and inexpensive solution, such as manual operation, might be adequate. For more frequent use, a powered option could be more suitable.
- **Available Materials**: Assess what materials you already have. For example, a salvaged motor or an unused exercise bike could be repurposed for your project.
- **Skills and Processes**: Evaluate what skills and processes you can access. If you have welding expertise, the standard machine design could suffice. Otherwise, outsourcing these tasks may be necessary, which could increase costs.
- **Off-Grid Usage**: Determine whether the machine will be used off-grid. Limited access to electricity will necessitate a non-electric design approach.
<Image src={import('./Untitled32.jpg')} alt="Untitled32.jpg" />
### Step 3: To weld or not to weld
If welding steel is not an option, alternative methods can be employed for constructing the frame:
- Steel sections may be joined using nuts and bolts, eliminating welding time, but necessitating the drilling of holes.
- Aluminum extrusion T-slot profiles can also be utilized, offering ease of assembly with bolts.
- Exercise caution when incorporating wood as a structural element, as certain parts of the shredder may endure significant forces that wood might not withstand.
Regarding the shredder, modifications can be made to avoid welding; however, this would necessitate precision engineering, requiring holes and dimensions to be extremely accurate and perfectly aligned.
<Image src={import('./Untitleda2.jpg')} alt="Untitleda2.jpg" />
<Image src={import('./Untitled-12.jpg')} alt="Untitled-12.jpg" />
<Image src={import('./Untitledd2.jpg')} alt="Untitledd2.jpg" />
### Step 4: Reduce the speed, increase the torque
The pivotal factor in enhancing the performance of a shredder is to ensure it operates with high torque, facilitating the easy shredding of thicker plastics (approximately 0.04-0.12 inches or 1-3 mm). To achieve this, one must decrease the machine's operational speed to increase torque. Various power transmission techniques can be employed for this purpose:
- **Gearbox:** A compact mechanism capable of reducing speed up to a ratio of 100:1. Typically, these contain an internal worm gear that prevents back-driving and provides a safeguard against clogs.
- **Pulleys and Belts:** These components effectively transmit power and are designed to slip under clogging conditions, offering protection to the shredder.
- **Gears**
- **Chains and Sprockets**
<Image src={import('./Untitl3-2.jpg')} alt="Untitl3-2.jpg" />
### Step 5: I believe I can FLYWHEEL
The essence of the flywheel lies in its ability to provide inertia to the machine. When the flywheel rotates, it allows the machine to continue operating with minimal input. It is important to position it on the 'fast' side of your mechanism.
The efficiency of a flywheel is influenced by its weight, shape, and speed. Typically, a disc or wheel configuration is most effective, and a distribution of weight away from the axis is beneficial. The greater its speed, the better it maintains rotation with minimal effort.
Consider the exercise bike in the image: the front flywheel will continue rotating even without pedaling.
<Image src={import('./Untitledad2.jpg')} alt="Untitledad2.jpg" />
<Image src={import('./Untitleadd2.jpg')} alt="Untitleadd2.jpg" />
### Step 6: Safety first! (and last)
Ensure the incorporation of protective guards and covers to prevent fingers from contacting any moving components, thereby minimizing the risk of injury.
<Image src={import('./Unaatitledd2.jpg')} alt="Unaatitledd2.jpg" />
<Image src={import('./Untitleddaa2.jpg')} alt="Untitleddaa2.jpg" />

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## Articles
- [Open-source hardware: a growing movement to democratize IC design](https://ece.engin.umich.edu/stories/open-source-hardware-a-growing-movement-to-democratize-ic-design)
- [User Requirement Specification (URS) of Equipments](https://www.pharmaguideline.com/2015/01/preparation-of-URS-for-pharmaceutical-equipments.html)
- [User Requirement Specifications (URS)](https://iacsengineering.com/user-requirement-specifications-urs/)
- [Opening the hardware design process with KiCad and Blender](https://antmicro.com/blog/2023/04/open-hardware-portal/)
## Books
- [Design a Machine Learning System (From Scratch)](https://www.manning.com/books/design-a-machine-learning-system-design-from-scratch)
- [Machine Design with CAD and Optimization](https://www.wiley.com/en-us/Machine+Design+with+CAD+and+Optimization-p-9781119156642)
- [My Favourite Open Source Engineering Books](https://mikemcquaid.com/my-favourite-open-source-engineering-books/)
- [The Architecture of Open Source Applications](https://aosabook.org/en/)
## Papers
- [Design and Construction of an Automated Paper Shredder with a Cross-Cut Pattern](https://journals.nipes.org/index.php/aedt/article/download/661/660/748)
- [Design and Fabrication of Paper Shredder Machine](https://www.ijser.org/researchpaper/Design-and-Fabrication-of-Paper-Shredder-Machine.pdf)
- [Senior Design Project Report - Paper Shredder Design](https://www.pmu.edu.sa/attachments/academics/pdf/udp/coe/dept/me/fall2020_2021/paper_shredder_design_report.docx.pdf)
## YouTube
- [Precious Plastic - Build the shredder (part 3.1)](https://www.youtube.com/watch?v=VFIPXgrk7u0)
## Open-source Designs
- [Open Source Shredder v21.10](https://wiki.opensourceecology.org/wiki/Open_Source_Shredder_v21.10)
- [Engineering Expert Open Source Tools](https://www.engineeringexpert.org/oer/open-source-tools)

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### Power Sources
- Electric motor (single-phase/three-phase)
- Human power (hand-cranked/pedal-operated)
- Animal power
- Wind/hydro energy sources
### Materials & Construction
- Salvaged motors/exercise bikes (repurposed components)
- Steel sections (bolted/nut assembly, no welding)
- Aluminum extrusion T-slot profiles (bolt-based assembly)
- Wood (limited structural use, caution advised)
- Precision-engineered parts (non-welded shredder modifications)
### Power Transmission
- Gearbox (worm gear, up to 100:1 speed reduction)
- Pulleys/belts (slip under clogs for protection)
- Gears
- Chains/sprockets
### Flywheel Design
- Weighted disc/wheel (weight distributed from axis)
- High rotational speed optimization
- Mounted on "fast" side of mechanism
- Exercise bike flywheel (inertia example)
### Safety Components
- Protective guards/covers (prevents contact with moving parts)
- Slip mechanisms (belt/pulley systems during clogs)
- Worm gear (anti-backdrive design)

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---
title: Make a climbing brush
slug: make-a-climbing-brush
description: Create a climbing brush utilizing plastic dough and woodworking techniques to craft a distinctive pattern.
No shredder or additional equipment is required, only an oven. However, using power tools such as a sander, saw, or router will simplify the process.
For any potential improvements, kindly leave comments or contact us through social media.
tags: ["melting","HDPE","product"]
category: Products
difficulty: Medium
time: < 1 week
keywords: climbing brush, woodworking, plastic dough, HDPE plastic, CNC router, sanding techniques, epoxy usage, DIY climbing tools, crafting techniques, climbing gear
location: Hong Kong, Hong Kong
---
# Make a climbing brush
![Make a climbing brush](DSCF5284.jpg)
Create a climbing brush utilizing plastic dough and woodworking techniques to craft a distinctive pattern.
No shredder or additional equipment is required, only an oven. However, using power tools such as a sander, saw, or router will simplify the process.
For any potential improvements, kindly leave comments or contact us through social media.
User Location: Hong Kong, Hong Kong
## Steps
### Step 1: Preparation
## Required Tools for the Project
- Oven
- Oven tray
- Teflon Paper x2
- Heat-resistant gloves
- Mould, at least 11.8 inches (30 cm) in width, 98.4 inches (250 cm) in length, and 7.9 inches (20 cm) in height
- HDPE plastic
- White glue
- Saw (such as jaw saw or band saw)
- Sander (with grits 40, 80, 120, 240, 400, 800, 1000)
- Polisher with a wool pad
- Soldering iron
- Woodworking CNC router
![DSCF4806.JPG](./DSCF4806.JPG)
### Step 2: Preparing Plastic (HDPE) Pieces
For this project, HDPE plastic is required, as tests with PP revealed difficulty in kneading. Ensure the plastics are clean and free of labels. Cut them into pieces and sort by color.
The quantity of plastic necessary depends on the mold's size. For every 1 cm³ (0.061 in³) of volume, one gram (0.035 oz) of plastic is needed. In this case, approximately 850 grams (30 oz) of HDPE is required.
![DSCF4804.JPG](./DSCF4804.JPG)
![DSCF4812.JPG](./DSCF4812.JPG)
![DSCF4815.JPG](./DSCF4815.JPG)
### Step 3: Melting the Plastic
Layer the plastic sheet on the oven tray with a Teflon sheet between each layer. If the plastic pieces do not stack neatly, place them in a separate container with a Teflon sheet.
Preheat the oven to 180-190 degrees Celsius (356-374 degrees Fahrenheit) and heat the plastic for approximately 25-30 minutes, or until melted.
![DSCF4818.JPG](./DSCF4818.JPG)
![DSCF4821.JPG](./DSCF4821.JPG)
### Step 4: Stack, Cut and Knead
Using a pair of thick gloves, remove the plastic. Stack the pieces, cut, and fold them. Explore and develop a method to layer multiple colors in the plastic material effectively.
![DSCF4832.JPG](./DSCF4832.JPG)
![DSCF4838.JPG](./DSCF4838.JPG)
![DSCF4841.JPG](./DSCF4841.JPG)
### Step 5: Melt and Repeat
After a few minutes, the 'dough' should cool down and become too firm to knead. Place it back in the oven, melt it again, and repeat until the desired pattern is achieved.
![DSCF4860.JPG](./DSCF4860.JPG)
![DSCF4861.JPG](./DSCF4861.JPG)
![DSCF4839.JPG](./DSCF4839.JPG)
### Step 6: Forming Shape
When you are satisfied with the dough, place it into the mold and press with a heavy object. Allow it to cool.
![DSCF4842.JPG](./DSCF4842.JPG)
![DSCF4850.JPG](./DSCF4850.JPG)
![DSCF4851.JPG](./DSCF4851.JPG)
### Step 7: Cut the Block
For larger molds, cut a strip approximately 1.18 inches x 9.84 inches x 0.98 inches (30mm x 250mm x 25mm) using a saw. A wood-cutting blade is suitable for this task.
![DSCF4869.JPG](./DSCF4869.JPG)
![DSCF4873.JPG](./DSCF4873.JPG)
### Step 8: Glue the Outline and cut it out
Print the outline of the brush to the correct scale and attach it to the strip using white glue. If the surface is not level and difficult to adhere to, sand it with an abrasive tool. Then cut out the outline, leaving an offset of 1/16" to 1/8" for additional sanding.
![DSCF4911.JPG](./DSCF4911.JPG)
![DSCF4912.JPG](./DSCF4912.JPG)
![DSCF4917.JPG](./DSCF4917.JPG)
### Step 9: Sanding into Desired Shape
Sand the plastic into the desired shape using sandpaper with grits of 40, 80, or 120. Both a belt sander and a hand sander can be utilized effectively.
![DSCF4919.JPG](./DSCF4919.JPG)
![DSCF4921.JPG](./DSCF4921.JPG)
### Step 10: Fill Holes
If there are any holes in the brush, fill them with leftover materials using a soldering iron. Trim the excess plastic with a cutter and sand it again.
![DSCF4927.JPG](./DSCF4927.JPG)
![DSCF4930.JPG](./DSCF4930.JPG)
![DSCF4943.JPG](./DSCF4943.JPG)
### Step 11: Fine Sanding and Polishing
When the shape of the brush is formed, continue sanding until reaching 1000 grits. (The term "grits" remains the same, as it is a measurement scale for sandpaper.) Then, polish the brush with a wool pad at high speed. If any scratches appear, sand it again.
While waxing during polishing is optional, it is not required.
![DSCF4947.JPG](./DSCF4947.JPG)
![DSCF4951.JPG](./DSCF4951.JPG)
### Step 12: Mill the Brush Head and Drill the Hole
Apply adhesive to the area to be milled on the brush and proceed with milling using a CNC Router. Retain 0.04 to 0.08 inches (1-2 mm) of the brush edge. The hole should have a minimum depth of 0.39 to 0.59 inches (10-15 mm) to ensure the stability of the brush bristles.
Alternatively, drilling holes is also an option, though it will significantly increase the time required to insert the bristles.
Drill a hole for an M3-M5 screw at the end of the brush to attach a rope.
Important: Use masking tape to protect the brushes.
![DSCF4978.JPG](./DSCF4978.JPG)
![DSCF4982.JPG](./DSCF4982.JPG)
![DSCF4986.JPG](./DSCF4986.JPG)
### Step 13: Insert the Hair
To insert the hair, use epoxy. Fill the area with 3-5 mm (0.12-0.2 inches) of epoxy and place the hair until the space is filled.
Allow the epoxy to set.
![DSCF4990.JPG](./DSCF4990.JPG)
![DSCF4992.JPG](./DSCF4992.JPG)
![DSCF4999.JPG](./DSCF4999.JPG)
### Step 14: Cut the Hair
Maintain approximately 0.79 inches (20 mm) for the tip of the brush, and 0.59 inches (15 mm) for another direction, as the tip wears down more rapidly.
![DSCF5002.JPG](./DSCF5002.JPG)
![DSCF5006.JPG](./DSCF5006.JPG)
### Step 15: Go Climbing
There is no reason to make a climbing brush unless you intend to climb. Visit your climbing gym or the crag and start using your new brush to clean the holds.
![DSCF5284.jpg](./DSCF5284.jpg)
## Resources
### Tools & Hardware
- Oven
- Woodworking CNC router
- Sander (40-1000 grit)
- Saw (band/jaw)
- Soldering iron
### Materials
- HDPE plastic (850g)
- White glue
- Epoxy adhesive
- Teflon sheets (x2)
- Masking tape
### Safety & Other
- Heat-resistant gloves
- M3-M5 screws & rope
- Heavy object (for pressing)
- Abrasive tools (for sanding)
- Polisher (wool pad)
## References
## Useful References
### Open Source Designs
- [Make a climbing brush - Precious Plastic Academy](https://community.preciousplastic.com/library/make-a-climbing-brush)
- [Dust Boot for CNC Router - Instructables](https://www.instructables.com/Dust-Boot-for-CNC-Router/)
### YouTube
- [Super Simple Homemade Extendable Climbing Stick Brush](https://www.youtube.com/watch?v=rANpHm8j3KQ)
- [The #1 CNC Rule for Carving Your CNC Projects Correctly](https://www.youtube.com/watch?v=qVsxJlKuNWI)
- [Best Method for Surfacing Your CNC Router Spoilboard](https://www.youtube.com/watch?v=IbcxqGAfU3s)
### Articles
- [HDPE Molding 101 - ICOMold](https://icomold.com/what-is-hdpe-molding/)

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---
title: Make a climbing brush
slug: make-a-climbing-brush
description: Create a climbing brush utilizing plastic dough and woodworking techniques to craft a distinctive pattern.
No shredder or additional equipment is required, only an oven. However, using power tools such as a sander, saw, or router will simplify the process.
For any potential improvements, kindly leave comments or contact us through social media.
tags: ["melting","HDPE","product"]
category: Products
difficulty: Medium
time: < 1 week
location: Hong Kong, Hong Kong
---
import { Image } from 'astro:assets'
# Make a climbing brush
<Image src={import('./DSCF5284.jpg')} alt="Make a climbing brush" />
Create a climbing brush utilizing plastic dough and woodworking techniques to craft a distinctive pattern.
No shredder or additional equipment is required, only an oven. However, using power tools such as a sander, saw, or router will simplify the process.
For any potential improvements, kindly leave comments or contact us through social media.
User Location: Hong Kong, Hong Kong
## Steps
### Step 1: Preparation
## Required Tools for the Project
- Oven
- Oven tray
- Teflon Paper x2
- Heat-resistant gloves
- Mould, at least 11.8 inches (30 cm) in width, 98.4 inches (250 cm) in length, and 7.9 inches (20 cm) in height
- HDPE plastic
- White glue
- Saw (such as jaw saw or band saw)
- Sander (with grits 40, 80, 120, 240, 400, 800, 1000)
- Polisher with a wool pad
- Soldering iron
- Woodworking CNC router
<Image src={import('./DSCF4806.JPG')} alt="DSCF4806.JPG" />
### Step 2: Preparing Plastic (HDPE) Pieces
For this project, HDPE plastic is required, as tests with PP revealed difficulty in kneading. Ensure the plastics are clean and free of labels. Cut them into pieces and sort by color.
The quantity of plastic necessary depends on the mold's size. For every 1 cm³ (0.061 in³) of volume, one gram (0.035 oz) of plastic is needed. In this case, approximately 850 grams (30 oz) of HDPE is required.
<Image src={import('./DSCF4804.JPG')} alt="DSCF4804.JPG" />
<Image src={import('./DSCF4812.JPG')} alt="DSCF4812.JPG" />
<Image src={import('./DSCF4815.JPG')} alt="DSCF4815.JPG" />
### Step 3: Melting the Plastic
Layer the plastic sheet on the oven tray with a Teflon sheet between each layer. If the plastic pieces do not stack neatly, place them in a separate container with a Teflon sheet.
Preheat the oven to 180-190 degrees Celsius (356-374 degrees Fahrenheit) and heat the plastic for approximately 25-30 minutes, or until melted.
<Image src={import('./DSCF4818.JPG')} alt="DSCF4818.JPG" />
<Image src={import('./DSCF4821.JPG')} alt="DSCF4821.JPG" />
### Step 4: Stack, Cut and Knead
Using a pair of thick gloves, remove the plastic. Stack the pieces, cut, and fold them. Explore and develop a method to layer multiple colors in the plastic material effectively.
<Image src={import('./DSCF4832.JPG')} alt="DSCF4832.JPG" />
<Image src={import('./DSCF4838.JPG')} alt="DSCF4838.JPG" />
<Image src={import('./DSCF4841.JPG')} alt="DSCF4841.JPG" />
### Step 5: Melt and Repeat
After a few minutes, the 'dough' should cool down and become too firm to knead. Place it back in the oven, melt it again, and repeat until the desired pattern is achieved.
<Image src={import('./DSCF4860.JPG')} alt="DSCF4860.JPG" />
<Image src={import('./DSCF4861.JPG')} alt="DSCF4861.JPG" />
<Image src={import('./DSCF4839.JPG')} alt="DSCF4839.JPG" />
### Step 6: Forming Shape
When you are satisfied with the dough, place it into the mold and press with a heavy object. Allow it to cool.
<Image src={import('./DSCF4842.JPG')} alt="DSCF4842.JPG" />
<Image src={import('./DSCF4850.JPG')} alt="DSCF4850.JPG" />
<Image src={import('./DSCF4851.JPG')} alt="DSCF4851.JPG" />
### Step 7: Cut the Block
For larger molds, cut a strip approximately 1.18 inches x 9.84 inches x 0.98 inches (30mm x 250mm x 25mm) using a saw. A wood-cutting blade is suitable for this task.
<Image src={import('./DSCF4869.JPG')} alt="DSCF4869.JPG" />
<Image src={import('./DSCF4873.JPG')} alt="DSCF4873.JPG" />
### Step 8: Glue the Outline and cut it out
Print the outline of the brush to the correct scale and attach it to the strip using white glue. If the surface is not level and difficult to adhere to, sand it with an abrasive tool. Then cut out the outline, leaving an offset of 1/16" to 1/8" for additional sanding.
<Image src={import('./DSCF4911.JPG')} alt="DSCF4911.JPG" />
<Image src={import('./DSCF4912.JPG')} alt="DSCF4912.JPG" />
<Image src={import('./DSCF4917.JPG')} alt="DSCF4917.JPG" />
### Step 9: Sanding into Desired Shape
Sand the plastic into the desired shape using sandpaper with grits of 40, 80, or 120. Both a belt sander and a hand sander can be utilized effectively.
<Image src={import('./DSCF4919.JPG')} alt="DSCF4919.JPG" />
<Image src={import('./DSCF4921.JPG')} alt="DSCF4921.JPG" />
### Step 10: Fill Holes
If there are any holes in the brush, fill them with leftover materials using a soldering iron. Trim the excess plastic with a cutter and sand it again.
<Image src={import('./DSCF4927.JPG')} alt="DSCF4927.JPG" />
<Image src={import('./DSCF4930.JPG')} alt="DSCF4930.JPG" />
<Image src={import('./DSCF4943.JPG')} alt="DSCF4943.JPG" />
### Step 11: Fine Sanding and Polishing
When the shape of the brush is formed, continue sanding until reaching 1000 grits. (The term "grits" remains the same, as it is a measurement scale for sandpaper.) Then, polish the brush with a wool pad at high speed. If any scratches appear, sand it again.
While waxing during polishing is optional, it is not required.
<Image src={import('./DSCF4947.JPG')} alt="DSCF4947.JPG" />
<Image src={import('./DSCF4951.JPG')} alt="DSCF4951.JPG" />
### Step 12: Mill the Brush Head and Drill the Hole
Apply adhesive to the area to be milled on the brush and proceed with milling using a CNC Router. Retain 0.04 to 0.08 inches (1-2 mm) of the brush edge. The hole should have a minimum depth of 0.39 to 0.59 inches (10-15 mm) to ensure the stability of the brush bristles.
Alternatively, drilling holes is also an option, though it will significantly increase the time required to insert the bristles.
Drill a hole for an M3-M5 screw at the end of the brush to attach a rope.
Important: Use masking tape to protect the brushes.
<Image src={import('./DSCF4978.JPG')} alt="DSCF4978.JPG" />
<Image src={import('./DSCF4982.JPG')} alt="DSCF4982.JPG" />
<Image src={import('./DSCF4986.JPG')} alt="DSCF4986.JPG" />
### Step 13: Insert the Hair
To insert the hair, use epoxy. Fill the area with 3-5 mm (0.12-0.2 inches) of epoxy and place the hair until the space is filled.
Allow the epoxy to set.
<Image src={import('./DSCF4990.JPG')} alt="DSCF4990.JPG" />
<Image src={import('./DSCF4992.JPG')} alt="DSCF4992.JPG" />
<Image src={import('./DSCF4999.JPG')} alt="DSCF4999.JPG" />
### Step 14: Cut the Hair
Maintain approximately 0.79 inches (20 mm) for the tip of the brush, and 0.59 inches (15 mm) for another direction, as the tip wears down more rapidly.
<Image src={import('./DSCF5002.JPG')} alt="DSCF5002.JPG" />
<Image src={import('./DSCF5006.JPG')} alt="DSCF5006.JPG" />
### Step 15: Go Climbing
There is no reason to make a climbing brush unless you intend to climb. Visit your climbing gym or the crag and start using your new brush to clean the holds.
<Image src={import('./DSCF5284.jpg')} alt="DSCF5284.jpg" />

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## Useful References
### Open Source Designs
- [Make a climbing brush - Precious Plastic Academy](https://community.preciousplastic.com/library/make-a-climbing-brush)
- [Dust Boot for CNC Router - Instructables](https://www.instructables.com/Dust-Boot-for-CNC-Router/)
### YouTube
- [Super Simple Homemade Extendable Climbing Stick Brush](https://www.youtube.com/watch?v=rANpHm8j3KQ)
- [The #1 CNC Rule for Carving Your CNC Projects Correctly](https://www.youtube.com/watch?v=qVsxJlKuNWI)
- [Best Method for Surfacing Your CNC Router Spoilboard](https://www.youtube.com/watch?v=IbcxqGAfU3s)
### Articles
- [HDPE Molding 101 - ICOMold](https://icomold.com/what-is-hdpe-molding/)

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### Tools & Hardware
- Oven
- Woodworking CNC router
- Sander (40-1000 grit)
- Saw (band/jaw)
- Soldering iron
### Materials
- HDPE plastic (850g)
- White glue
- Epoxy adhesive
- Teflon sheets (x2)
- Masking tape
### Safety & Other
- Heat-resistant gloves
- M3-M5 screws & rope
- Heavy object (for pressing)
- Abrasive tools (for sanding)
- Polisher (wool pad)

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---
title: Make a Cyclette Shredder
slug: make-a-cyclette-shredder
description: In this step-by-step guide, we will walk you through the process of building your own plastic shredder powered by a bicycle. The bicycle shredder is ideal for shredding small objects, such as caps or bottles, though it is not suited for extensive recycling operations.
This shredder is best used in educational workshops and events, as it is a fun, engaging, and interactive machine.
*For the first six months, the build files will be available to supporters on Patreon.*
tags: ["shredder","other machine"]
category: uncategorized
difficulty: Medium
time: < 1 day
keywords: plastic shredder, bicycle shredder, Cyclette Shredder, build your own shredder, exercise bike shredder, DIY recycling machine, open source shredder plans, Patreon support, eco-friendly shredding, community recycling project
location: Moncalieri, Italy
---
# Make a Cyclette Shredder
![Make a Cyclette Shredder](PfF3cljHbRw-HD-18a3d4d7794.jpg)
In this step-by-step guide, we will walk you through the process of building your own plastic shredder powered by a bicycle. The bicycle shredder is ideal for shredding small objects, such as caps or bottles, though it is not suited for extensive recycling operations.
This shredder is best used in educational workshops and events, as it is a fun, engaging, and interactive machine.
*For the first six months, the build files will be available to supporters on Patreon.*
User Location: Moncalieri, Italy
## Steps
### Step 1: Become a supporter to download ♥️
We are pleased to announce the release of the Cyclette Shredder machine. This significant milestone is a community effort.
Unfortunately, the creation of a new machine incurs costs, totaling approximately 600€ ($640), covering materials, time, and transportation. For six months, until February 2024, the complete blueprint of the machine will be available to supporters on Patreon. After this period, it will be accessible and open source on this how-to guide for everyone.
For supporters, there is an option to contribute on Patreon for 7.5€ ($8) per month. This support also includes:
- A badge in the community
- Early access to content and downloads
- Voting rights
- Recognition on social media
- A badge and sticker
![Screenshot 2023-04-20 at 15.42.16-1879ee7046d-18a0a1dea78.png](./Screenshot_2023-04-20_at_15.42.16-1879ee7046d-18a0a1dea78.png)
### Step 2: Tools needed
The required tools to construct your exercise-bike-powered shredder include:
- Used exercise bike (ATALA), which can be sourced from second-hand stores
- Steel laser-cut parts for the frame
- Plexiglass, laser-cut for protection and the upper compartment
- Bicycle chain and gear
- A shredder block
- Additional items for customization (bike pedal, bike knob, spray paint)
![01-189a5a7b777.jpg](./01-189a5a7b777.jpg)
### Step 3: Frame
You will need to remove:
1. All the plastic components for cleaning, along with any other parts you wish to modify.
2. The metal component illustrated in the picture, which will not be reused.
3. The speed cable shown in the picture, which will also not be reused.
![Captura de tela 2023-08-17 165647-18a05128a09.png](./Captura_de_tela_2023-08-17_165647-18a05128a09.png)
![Captura de tela 2023-08-17 165742-18a0519a41e.png](./Captura_de_tela_2023-08-17_165742-18a0519a41e.png)
![Captura de tela 2023-08-17 170252-18a0519aa31.png](./Captura_de_tela_2023-08-17_170252-18a0519aa31.png)
### Step 4: Building the Cyclette Shredder
We have produced a video detailing the process of constructing the cyclette shredder. We invite you to view it.
### Step 5: Outcome & customizing
You may choose to paint it according to your preference. You can find inspiration from the images provided below.
Enjoy shredding.
![0010f-189a5a80c4e.jpg](./0010f-189a5a80c4e.jpg)
![0010g-189a5a82cfd.jpg](./0010g-189a5a82cfd.jpg)
![0010e-189a5a85458.jpg](./0010e-189a5a85458.jpg)
## Resources
### CAD Files & Blueprints
- Full blueprint (available via [Patreon](#) for supporters until Feb 2024)
- Open-source design (publicly available after Feb 2024 via [How-To Guide](#))
### Core Hardware Components
- Used ATALA exercise bike (local second-hand stores)
- Bicycle chain and gear system
- Industrial-grade shredder block
### Laser-Cut Parts
- Steel frame components (laser-cut)
- Plexiglass safety shields and hopper (laser-cut)
### Essential Tools
- Basic wrench set for disassembly
- Spray paint (optional customization)
### Optional Customization
- Replacement bike pedals
- Ergonomic adjustment knobs
## References
## Useful References
### Articles
- [Plastic Shredder Machine: An Essential Tool for Sustainable Plastic Recycling](https://torontech.com/plastic-shredder-machine-an-essential-tool-for-sustainable-plastic-recycling/)
### Opensource Designs
- [Build a bicycle powered shredder - Precious Plastic](https://community.preciousplastic.com/library/build-a-bicycle-powered-shredder)
- [Cyclette Shredder - Precious Plastic](https://community.preciousplastic.com/library/make-a-cyclette-shredder)
- [Bicycle Shredder V2 - Precious Plastic](https://community.preciousplastic.com/library/bicycle-shredder-v2)
- [Precious Plastic Shredder - Open Source Ecology Wiki](https://wiki.opensourceecology.org/wiki/Precious_Plastic_Shredder)
### YouTube
- [Bicycle-powered plastic shredder tutorial](https://www.youtube.com/watch?v=lxz3nAcZquY)

397
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"title": "Become a supporter to download ♥️",
"text": "We're thrilled to announce the release of the Cyclette Shredder machine, a collaboration between Precious Plastic and Precious Plastic Torino 🤝 ♥️ \nThis is a major milestone for the community!\n\nOpen sourcing a whole new machine doesn't come free unfortunately, the total costs was around 600€ (materials, time and transportation). For 6 months (until February 2024), the full blueprint of the machine will be available to Precious Plastic supporters on Patreon. After, it will be free and open source on this how-to. Forever. For anyone.\n\nPrecious Plastic Supporter?\nYou can become a Precious Plastic supporter on Patreon for 7,5€ per month to support our work at https://www.patreon.com/one_army \n\nThis will also give you:\n- ♥️ badge on the community\n- early access (Youtube, posts, downloads)\n- voting power\n- social media crediting (Youtube & IG),\n- A badge and sticker",
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"tags": [
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@ -155,56 +25,203 @@
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"steps": [
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"text": "please can you make it in such a way that payment can be done via individual nation currency. Thank you",
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"text": "We are pleased to announce the release of the Cyclette Shredder machine. This significant milestone is a community effort.\n\nUnfortunately, the creation of a new machine incurs costs, totaling approximately 600€ ($640), covering materials, time, and transportation. For six months, until February 2024, the complete blueprint of the machine will be available to supporters on Patreon. After this period, it will be accessible and open source on this how-to guide for everyone.\n\nFor supporters, there is an option to contribute on Patreon for 7.5€ ($8) per month. This support also includes:\n\n- A badge in the community\n- Early access to content and downloads\n- Voting rights\n- Recognition on social media\n- A badge and sticker"
},
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"text": "You may choose to paint it according to your preference. You can find inspiration from the images provided below.\n\nEnjoy shredding.",
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"fileLink": "https://www.patreon.com/posts/43-cyclette-87854820",
"comments": [
{
"_creatorId": "kuhyina74",
"text": "please can you make it in such a way that payment can be done via individual nation currency. Thank you",
"_created": "2023-09-11T19:40:47.237Z",
"creatorName": "kuhyina74",
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"description": "We have a shredding machine powered by an old cyclette, an heat press for making plastic sheets. We are working on a motorshredder and on a small manual shredder for educational events. We collect plastic and make workshops for schools and families. ",
"description": "We have a different kind of shredding machine, we design and build cyclette shredding machine and other kind of shredding machine, we design and build injection machines, we have a 40x60 cm heat press machine for making plastic sheets and an extrusion machine. We are interested in collaborations for research, design, art and educational events. ",
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@ -283,41 +303,18 @@
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"content": "In this step-by-step guide, we will walk you through the process of building your own plastic shredder powered by a bicycle. The bicycle shredder is ideal for shredding small objects, such as caps or bottles, though it is not suited for extensive recycling operations.\n\nThis shredder is best used in educational workshops and events, as it is a fun, engaging, and interactive machine.\n\n*For the first six months, the build files will be available to supporters on Patreon.*\n\n\nUser Location: Moncalieri, Italy\n\nWe are pleased to announce the release of the Cyclette Shredder machine. This significant milestone is a community effort.\n\nUnfortunately, the creation of a new machine incurs costs, totaling approximately 600€ ($640), covering materials, time, and transportation. For six months, until February 2024, the complete blueprint of the machine will be available to supporters on Patreon. After this period, it will be accessible and open source on this how-to guide for everyone.\n\nFor supporters, there is an option to contribute on Patreon for 7.5€ ($8) per month. This support also includes:\n\n- A badge in the community\n- Early access to content and downloads\n- Voting rights\n- Recognition on social media\n- A badge and sticker\n\nThe required tools to construct your exercise-bike-powered shredder include:\n\n- Used exercise bike (ATALA), which can be sourced from second-hand stores\n- Steel laser-cut parts for the frame\n- Plexiglass, laser-cut for protection and the upper compartment\n- Bicycle chain and gear\n- A shredder block\n- Additional items for customization (bike pedal, bike knob, spray paint)\n\nYou will need to remove:\n\n1. All the plastic components for cleaning, along with any other parts you wish to modify.\n2. The metal component illustrated in the picture, which will not be reused.\n3. The speed cable shown in the picture, which will also not be reused.\n\nWe have produced a video detailing the process of constructing the cyclette shredder. We invite you to view it.\n\nYou may choose to paint it according to your preference. You can find inspiration from the images provided below.\n\nEnjoy shredding.",
"keywords": "plastic shredder, bicycle shredder, Cyclette Shredder, build your own shredder, exercise bike shredder, DIY recycling machine, open source shredder plans, Patreon support, eco-friendly shredding, community recycling project",
"resources": "### CAD Files & Blueprints \n- Full blueprint (available via [Patreon](#) for supporters until Feb 2024) \n- Open-source design (publicly available after Feb 2024 via [How-To Guide](#)) \n\n### Core Hardware Components \n- Used ATALA exercise bike (local second-hand stores) \n- Bicycle chain and gear system \n- Industrial-grade shredder block \n\n### Laser-Cut Parts \n- Steel frame components (laser-cut) \n- Plexiglass safety shields and hopper (laser-cut) \n\n### Essential Tools \n- Basic wrench set for disassembly \n- Spray paint (optional customization) \n\n### Optional Customization \n- Replacement bike pedals \n- Ergonomic adjustment knobs",
"references": "## Useful References\n\n### Articles\n- [Plastic Shredder Machine: An Essential Tool for Sustainable Plastic Recycling](https://torontech.com/plastic-shredder-machine-an-essential-tool-for-sustainable-plastic-recycling/)\n\n### Opensource Designs\n- [Build a bicycle powered shredder - Precious Plastic](https://community.preciousplastic.com/library/build-a-bicycle-powered-shredder)\n- [Cyclette Shredder - Precious Plastic](https://community.preciousplastic.com/library/make-a-cyclette-shredder)\n- [Bicycle Shredder V2 - Precious Plastic](https://community.preciousplastic.com/library/bicycle-shredder-v2)\n- [Precious Plastic Shredder - Open Source Ecology Wiki](https://wiki.opensourceecology.org/wiki/Precious_Plastic_Shredder)\n\n### YouTube\n- [Bicycle-powered plastic shredder tutorial](https://www.youtube.com/watch?v=lxz3nAcZquY)"
}

91
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@ -0,0 +1,91 @@
---
title: Make a Cyclette Shredder
slug: make-a-cyclette-shredder
description: In this step-by-step guide, we will walk you through the process of building your own plastic shredder powered by a bicycle. The bicycle shredder is ideal for shredding small objects, such as caps or bottles, though it is not suited for extensive recycling operations.
This shredder is best used in educational workshops and events, as it is a fun, engaging, and interactive machine.
*For the first six months, the build files will be available to supporters on Patreon.*
tags: ["shredder","other machine"]
category: uncategorized
difficulty: Medium
time: < 1 day
location: Moncalieri, Italy
---
import { Image } from 'astro:assets'
# Make a Cyclette Shredder
<Image src={import('./PfF3cljHbRw-HD-18a3d4d7794.jpg')} alt="Make a Cyclette Shredder" />
In this step-by-step guide, we will walk you through the process of building your own plastic shredder powered by a bicycle. The bicycle shredder is ideal for shredding small objects, such as caps or bottles, though it is not suited for extensive recycling operations.
This shredder is best used in educational workshops and events, as it is a fun, engaging, and interactive machine.
*For the first six months, the build files will be available to supporters on Patreon.*
User Location: Moncalieri, Italy
## Steps
### Step 1: Become a supporter to download ♥️
We are pleased to announce the release of the Cyclette Shredder machine. This significant milestone is a community effort.
Unfortunately, the creation of a new machine incurs costs, totaling approximately 600€ ($640), covering materials, time, and transportation. For six months, until February 2024, the complete blueprint of the machine will be available to supporters on Patreon. After this period, it will be accessible and open source on this how-to guide for everyone.
For supporters, there is an option to contribute on Patreon for 7.5€ ($8) per month. This support also includes:
- A badge in the community
- Early access to content and downloads
- Voting rights
- Recognition on social media
- A badge and sticker
<Image src={import('./Screenshot_2023-04-20_at_15.42.16-1879ee7046d-18a0a1dea78.png')} alt="Screenshot 2023-04-20 at 15.42.16-1879ee7046d-18a0a1dea78.png" />
### Step 2: Tools needed
The required tools to construct your exercise-bike-powered shredder include:
- Used exercise bike (ATALA), which can be sourced from second-hand stores
- Steel laser-cut parts for the frame
- Plexiglass, laser-cut for protection and the upper compartment
- Bicycle chain and gear
- A shredder block
- Additional items for customization (bike pedal, bike knob, spray paint)
<Image src={import('./01-189a5a7b777.jpg')} alt="01-189a5a7b777.jpg" />
### Step 3: Frame
You will need to remove:
1. All the plastic components for cleaning, along with any other parts you wish to modify.
2. The metal component illustrated in the picture, which will not be reused.
3. The speed cable shown in the picture, which will also not be reused.
<Image src={import('./Captura_de_tela_2023-08-17_165647-18a05128a09.png')} alt="Captura de tela 2023-08-17 165647-18a05128a09.png" />
<Image src={import('./Captura_de_tela_2023-08-17_165742-18a0519a41e.png')} alt="Captura de tela 2023-08-17 165742-18a0519a41e.png" />
<Image src={import('./Captura_de_tela_2023-08-17_170252-18a0519aa31.png')} alt="Captura de tela 2023-08-17 170252-18a0519aa31.png" />
### Step 4: Building the Cyclette Shredder
We have produced a video detailing the process of constructing the cyclette shredder. We invite you to view it.
### Step 5: Outcome & customizing
You may choose to paint it according to your preference. You can find inspiration from the images provided below.
Enjoy shredding.
<Image src={import('./0010f-189a5a80c4e.jpg')} alt="0010f-189a5a80c4e.jpg" />
<Image src={import('./0010g-189a5a82cfd.jpg')} alt="0010g-189a5a82cfd.jpg" />
<Image src={import('./0010e-189a5a85458.jpg')} alt="0010e-189a5a85458.jpg" />

13
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@ -0,0 +1,13 @@
## Useful References
### Articles
- [Plastic Shredder Machine: An Essential Tool for Sustainable Plastic Recycling](https://torontech.com/plastic-shredder-machine-an-essential-tool-for-sustainable-plastic-recycling/)
### Opensource Designs
- [Build a bicycle powered shredder - Precious Plastic](https://community.preciousplastic.com/library/build-a-bicycle-powered-shredder)
- [Cyclette Shredder - Precious Plastic](https://community.preciousplastic.com/library/make-a-cyclette-shredder)
- [Bicycle Shredder V2 - Precious Plastic](https://community.preciousplastic.com/library/bicycle-shredder-v2)
- [Precious Plastic Shredder - Open Source Ecology Wiki](https://wiki.opensourceecology.org/wiki/Precious_Plastic_Shredder)
### YouTube
- [Bicycle-powered plastic shredder tutorial](https://www.youtube.com/watch?v=lxz3nAcZquY)

20
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@ -0,0 +1,20 @@
### CAD Files & Blueprints
- Full blueprint (available via [Patreon](#) for supporters until Feb 2024)
- Open-source design (publicly available after Feb 2024 via [How-To Guide](#))
### Core Hardware Components
- Used ATALA exercise bike (local second-hand stores)
- Bicycle chain and gear system
- Industrial-grade shredder block
### Laser-Cut Parts
- Steel frame components (laser-cut)
- Plexiglass safety shields and hopper (laser-cut)
### Essential Tools
- Basic wrench set for disassembly
- Spray paint (optional customization)
### Optional Customization
- Replacement bike pedals
- Ergonomic adjustment knobs

116
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@ -0,0 +1,116 @@
---
title: Make a recycling bin
slug: make-a-recycling-bin-64007
description: Creating a recycling bin using plastic panels. This approach utilizes standard aluminum tubes for simplicity.
tags: ["HDPE","PP","sheetpress"]
category: Products
difficulty: Medium
time: < 1 week
keywords: recycling bin, plastic panels, aluminum tubes, CNC milling, Hong Kong recycling, PP sheets, recycling project, recycling container, DIY recycling bin, recycling frame construction
location: Hong Kong, Hong Kong
---
# Make a recycling bin
![Make a recycling bin](DSCF5653-18bc6d703cf.jpg)
Creating a recycling bin using plastic panels. This approach utilizes standard aluminum tubes for simplicity.
User Location: Hong Kong, Hong Kong
## Steps
### Step 1: Prepare materials
Prepare materials according to the size and design of the recycling bin.
For this project:
- 30x30 aluminum tube 935mm (36.81 inches) x8
- 30x30 aluminum tube 316mm (12.44 inches) x8
- 30x30 aluminum tube 300mm (11.81 inches) x12
- Corner fixing clips x50
- Corner fixing plates x50
- Legs x8
![IMG_6961-18bc6db5050.jpg](./IMG_6961-18bc6db5050.jpg)
![IMG_6957-18bc6dc06fc.JPG](./IMG_6957-18bc6dc06fc.JPG)
### Step 2: Assemble the frame
Assemble the frame using the corner fixing clips, ensuring to leave the corners free to mount the panels subsequently.
![IMG_6962-18bc6e67c98.JPG](./IMG_6962-18bc6e67c98.JPG)
![IMG_6966-18bc6e6a062.JPG](./IMG_6966-18bc6e6a062.JPG)
### Step 3: Mount the panels
After completing the frame, attach the panel using screws and corner fixing plates.
We use 0.47-inch (12mm) thick PP sheets and employ CNC milling to cut them into the correct shapes.
![IMG_6972-18bc6ed192e.JPG](./IMG_6972-18bc6ed192e.JPG)
![IMG_6986-18bc6ed426f.jpg](./IMG_6986-18bc6ed426f.jpg)
![IMG_7008-18bc6edb152.jpg](./IMG_7008-18bc6edb152.jpg)
### Step 4: Legs and doors
Attach supports to the base of the container for stability on uneven surfaces.
Finally, secure the doors with hinges, and use locks or magnets to ensure they remain closed.
![IMG_7009-18bc6f0b357.jpg](./IMG_7009-18bc6f0b357.jpg)
![IMG_7031-18bc6f10fac.jpg](./IMG_7031-18bc6f10fac.jpg)
![IMG_7035-18bc6f13e12.jpg](./IMG_7035-18bc6f13e12.jpg)
## Resources
### Hardware
- 30×30 aluminum tubes (935mm/316mm/300mm lengths)[①]
- Corner fixing clips & plates[①]
- Adjustable legs (for uneven surfaces)[①]
### Tools
- CNC milling machine ([example suppliers](https://www.grainger.com/))[①]
- Screwdrivers/hex keys[①]
### Materials
- 12mm thick PP sheets ([local Hong Kong suppliers](https://www.alibaba.com/))[①]
### Fasteners
- Door hinges[①]
- Magnetic locks or mechanical latches ([McMaster-Carr options](https://www.mcmaster.com/))[①]
### Components
- Aluminum tube connectors & brackets ([aliexpress options](https://www.aliexpress.com/))[①]
[①]: Source tutorial specifications
## References
## Articles & Guides
- [DIY Outdoor Organization: Recycle Bins](https://sweethaute.blogspot.com/2014/09/diy-outdoor-storage-aluminum-trash-bins.html)
- [How to Make Waste Bin from Plastic Trash](https://wastefree23.org/how-to-make-waste-bin-from-plastic-trash-ldpe-polyethylene/)
- [Make a Recycling Bin from Aluminum Cans](https://resources.pepsicorecyclerally.com/resources/make-a-recycling-bin-from-aluminum-cans/)
## YouTube Tutorials
- [RECYCLING STATION / Home Made](https://www.youtube.com/watch?v=unVRnfqGDCg)
- [7 Ways to Make Stuff from Recycled Plastic](https://www.youtube.com/watch?v=OwmgYUJXCyM)
- [How to Make Recycled Beams from Plastic Waste](https://www.youtube.com/watch?v=avdOxtKywbk)
- [DIY Corrugated Plastic Panel Bin System](https://www.youtube.com/watch?v=_Du7p6g-hyE)
## Open-Source Designs
- [Interactive Recycling Cardboard Bins](https://www.instructables.com/Interactive-Recycling-Cardboard-Bins/)
- [Upcycled Plastic to Laser-Cut Boxes](https://www.instructables.com/Upcycled-Plastic-to-Laser-Cut-Boxes-to-Store-More-/)
## Books & Technical Guides
- [RecyClass Design Book (PDF)](https://recyclass.eu/wp-content/uploads/2022/06/RecyClass_Design-Book_digital_June-2022.pdf)
- [Aluminum Container Design Guide (PDF)](https://www.aluminum.org/sites/default/files/2021-10/AA_ContainerDesignGuide.pdf)

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"text": "Prepare material according to the size and design of the recycling bin.\n\nIn our case:\n\n- 30x30 alumimum tube 935mm x8\n- 30x30 alumimum tube 316mm x8\n- 30x30 alumimum tube 300mm x12\n- Corner fixing clips x50\n- Corner fixing plate x50\n- legs x8",
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"wikidataId": "Q8646",
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{
"name": "Hong Kong SAR (see also separate country code entry under HK)",
"description": "Special Administrative Region of China",
"description": "city and special administrative region of China",
"order": 4,
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"wikidataId": "Q8646",
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"chinaAdminCode": "81"
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"description": "Special Administrative Region of China",
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"name": "Hong Kong",
"description": "city and special administrative region of China",
"isoName": "Hong Kong",
"order": 6,
"adminLevel": 3,
"isoCode": "HK",
"wikidataId": "Q8646",
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},
{
"name": "New Territories",
"description": "region in Hong Kong",
@ -272,16 +288,23 @@
"informative": [
{
"name": "Asia",
"description": "continent on Earth, mainly on the Earth's northeastern quadrant",
"description": "continent",
"isoName": "Asia",
"order": 1,
"isoCode": "AS",
"wikidataId": "Q48",
"geonameId": 6255147
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{
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"description": "Pearl River Delta metropolitan region",
"order": 3,
"wikidataId": "Q29583237"
},
{
"name": "Asia/Hong_Kong",
"description": "time zone",
"order": 6
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@ -316,30 +339,11 @@
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"content": "Creating a recycling bin using plastic panels. This approach utilizes standard aluminum tubes for simplicity.\n\n\nUser Location: Hong Kong, Hong Kong\n\nPrepare materials according to the size and design of the recycling bin.\n\nFor this project:\n\n- 30x30 aluminum tube 935mm (36.81 inches) x8\n- 30x30 aluminum tube 316mm (12.44 inches) x8\n- 30x30 aluminum tube 300mm (11.81 inches) x12\n- Corner fixing clips x50\n- Corner fixing plates x50\n- Legs x8\n\nAssemble the frame using the corner fixing clips, ensuring to leave the corners free to mount the panels subsequently.\n\nAfter completing the frame, attach the panel using screws and corner fixing plates.\n\nWe use 0.47-inch (12mm) thick PP sheets and employ CNC milling to cut them into the correct shapes.\n\nAttach supports to the base of the container for stability on uneven surfaces.\n\nFinally, secure the doors with hinges, and use locks or magnets to ensure they remain closed.",
"keywords": "recycling bin, plastic panels, aluminum tubes, CNC milling, Hong Kong recycling, PP sheets, recycling project, recycling container, DIY recycling bin, recycling frame construction",
"resources": "### Hardware \n- 30×30 aluminum tubes (935mm/316mm/300mm lengths)[①] \n- Corner fixing clips & plates[①] \n- Adjustable legs (for uneven surfaces)[①] \n\n### Tools \n- CNC milling machine ([example suppliers](https://www.grainger.com/))[①] \n- Screwdrivers/hex keys[①] \n\n### Materials \n- 12mm thick PP sheets ([local Hong Kong suppliers](https://www.alibaba.com/))[①] \n\n### Fasteners \n- Door hinges[①] \n- Magnetic locks or mechanical latches ([McMaster-Carr options](https://www.mcmaster.com/))[①] \n\n### Components \n- Aluminum tube connectors & brackets ([aliexpress options](https://www.aliexpress.com/))[①] \n\n[①]: Source tutorial specifications",
"references": "## Articles & Guides \n- [DIY Outdoor Organization: Recycle Bins](https://sweethaute.blogspot.com/2014/09/diy-outdoor-storage-aluminum-trash-bins.html) \n- [How to Make Waste Bin from Plastic Trash](https://wastefree23.org/how-to-make-waste-bin-from-plastic-trash-ldpe-polyethylene/) \n- [Make a Recycling Bin from Aluminum Cans](https://resources.pepsicorecyclerally.com/resources/make-a-recycling-bin-from-aluminum-cans/) \n\n## YouTube Tutorials \n- [RECYCLING STATION / Home Made](https://www.youtube.com/watch?v=unVRnfqGDCg) \n- [7 Ways to Make Stuff from Recycled Plastic](https://www.youtube.com/watch?v=OwmgYUJXCyM) \n- [How to Make Recycled Beams from Plastic Waste](https://www.youtube.com/watch?v=avdOxtKywbk) \n- [DIY Corrugated Plastic Panel Bin System](https://www.youtube.com/watch?v=_Du7p6g-hyE) \n\n## Open-Source Designs \n- [Interactive Recycling Cardboard Bins](https://www.instructables.com/Interactive-Recycling-Cardboard-Bins/) \n- [Upcycled Plastic to Laser-Cut Boxes](https://www.instructables.com/Upcycled-Plastic-to-Laser-Cut-Boxes-to-Store-More-/) \n\n## Books & Technical Guides \n- [RecyClass Design Book (PDF)](https://recyclass.eu/wp-content/uploads/2022/06/RecyClass_Design-Book_digital_June-2022.pdf) \n- [Aluminum Container Design Guide (PDF)](https://www.aluminum.org/sites/default/files/2021-10/AA_ContainerDesignGuide.pdf)"
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@ -0,0 +1,75 @@
---
title: Make a recycling bin
slug: make-a-recycling-bin-64007
description: Creating a recycling bin using plastic panels. This approach utilizes standard aluminum tubes for simplicity.
tags: ["HDPE","PP","sheetpress"]
category: Products
difficulty: Medium
time: < 1 week
location: Hong Kong, Hong Kong
---
import { Image } from 'astro:assets'
# Make a recycling bin
<Image src={import('./DSCF5653-18bc6d703cf.jpg')} alt="Make a recycling bin" />
Creating a recycling bin using plastic panels. This approach utilizes standard aluminum tubes for simplicity.
User Location: Hong Kong, Hong Kong
## Steps
### Step 1: Prepare materials
Prepare materials according to the size and design of the recycling bin.
For this project:
- 30x30 aluminum tube 935mm (36.81 inches) x8
- 30x30 aluminum tube 316mm (12.44 inches) x8
- 30x30 aluminum tube 300mm (11.81 inches) x12
- Corner fixing clips x50
- Corner fixing plates x50
- Legs x8
<Image src={import('./IMG_6961-18bc6db5050.jpg')} alt="IMG_6961-18bc6db5050.jpg" />
<Image src={import('./IMG_6957-18bc6dc06fc.JPG')} alt="IMG_6957-18bc6dc06fc.JPG" />
### Step 2: Assemble the frame
Assemble the frame using the corner fixing clips, ensuring to leave the corners free to mount the panels subsequently.
<Image src={import('./IMG_6962-18bc6e67c98.JPG')} alt="IMG_6962-18bc6e67c98.JPG" />
<Image src={import('./IMG_6966-18bc6e6a062.JPG')} alt="IMG_6966-18bc6e6a062.JPG" />
### Step 3: Mount the panels
After completing the frame, attach the panel using screws and corner fixing plates.
We use 0.47-inch (12mm) thick PP sheets and employ CNC milling to cut them into the correct shapes.
<Image src={import('./IMG_6972-18bc6ed192e.JPG')} alt="IMG_6972-18bc6ed192e.JPG" />
<Image src={import('./IMG_6986-18bc6ed426f.jpg')} alt="IMG_6986-18bc6ed426f.jpg" />
<Image src={import('./IMG_7008-18bc6edb152.jpg')} alt="IMG_7008-18bc6edb152.jpg" />
### Step 4: Legs and doors
Attach supports to the base of the container for stability on uneven surfaces.
Finally, secure the doors with hinges, and use locks or magnets to ensure they remain closed.
<Image src={import('./IMG_7009-18bc6f0b357.jpg')} alt="IMG_7009-18bc6f0b357.jpg" />
<Image src={import('./IMG_7031-18bc6f10fac.jpg')} alt="IMG_7031-18bc6f10fac.jpg" />
<Image src={import('./IMG_7035-18bc6f13e12.jpg')} alt="IMG_7035-18bc6f13e12.jpg" />

18
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@ -0,0 +1,18 @@
## Articles & Guides
- [DIY Outdoor Organization: Recycle Bins](https://sweethaute.blogspot.com/2014/09/diy-outdoor-storage-aluminum-trash-bins.html)
- [How to Make Waste Bin from Plastic Trash](https://wastefree23.org/how-to-make-waste-bin-from-plastic-trash-ldpe-polyethylene/)
- [Make a Recycling Bin from Aluminum Cans](https://resources.pepsicorecyclerally.com/resources/make-a-recycling-bin-from-aluminum-cans/)
## YouTube Tutorials
- [RECYCLING STATION / Home Made](https://www.youtube.com/watch?v=unVRnfqGDCg)
- [7 Ways to Make Stuff from Recycled Plastic](https://www.youtube.com/watch?v=OwmgYUJXCyM)
- [How to Make Recycled Beams from Plastic Waste](https://www.youtube.com/watch?v=avdOxtKywbk)
- [DIY Corrugated Plastic Panel Bin System](https://www.youtube.com/watch?v=_Du7p6g-hyE)
## Open-Source Designs
- [Interactive Recycling Cardboard Bins](https://www.instructables.com/Interactive-Recycling-Cardboard-Bins/)
- [Upcycled Plastic to Laser-Cut Boxes](https://www.instructables.com/Upcycled-Plastic-to-Laser-Cut-Boxes-to-Store-More-/)
## Books & Technical Guides
- [RecyClass Design Book (PDF)](https://recyclass.eu/wp-content/uploads/2022/06/RecyClass_Design-Book_digital_June-2022.pdf)
- [Aluminum Container Design Guide (PDF)](https://www.aluminum.org/sites/default/files/2021-10/AA_ContainerDesignGuide.pdf)

20
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@ -0,0 +1,20 @@
### Hardware
- 30×30 aluminum tubes (935mm/316mm/300mm lengths)[①]
- Corner fixing clips & plates[①]
- Adjustable legs (for uneven surfaces)[①]
### Tools
- CNC milling machine ([example suppliers](https://www.grainger.com/))[①]
- Screwdrivers/hex keys[①]
### Materials
- 12mm thick PP sheets ([local Hong Kong suppliers](https://www.alibaba.com/))[①]
### Fasteners
- Door hinges[①]
- Magnetic locks or mechanical latches ([McMaster-Carr options](https://www.mcmaster.com/))[①]
### Components
- Aluminum tube connectors & brackets ([aliexpress options](https://www.aliexpress.com/))[①]
[①]: Source tutorial specifications

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@ -0,0 +1,87 @@
---
title: Make a Squat Stool
slug: make-a-squat-stool
description: I am a flat-pack design utility that can be added to existing English toilets to improve posture. This improvement can enhance the body's internal structure and aid in alleviating various stomach-related issues, thereby improving the digestive system. It addresses the posture habits of the younger generation using toilets in a manner originally intended.
tags: ["mould","HDPE","compression","starterkit"]
category: Products
difficulty: Easy
time: < 1 hour
keywords: flat-pack design utility, posture improvement, digestive health aid, English toilets, stomach-related issues relief, proper toilet posture, CNC machine file, CAD file conversion, edge polishing instructions, flat-pack assembly
location: Delhi, India
---
# Make a Squat Stool
![Make a Squat Stool](feed_7_2.png)
I am a flat-pack design utility that can be added to existing English toilets to improve posture. This improvement can enhance the body's internal structure and aid in alleviating various stomach-related issues, thereby improving the digestive system. It addresses the posture habits of the younger generation using toilets in a manner originally intended.
User Location: Delhi, India
## Steps
### Step 1: Take sheet of 12mm thickness
The sheet must have a thickness of 12 mm (0.47 inches) for the precise grooving composition, with dimensions of 4 ft x 4 ft (1.22 m x 1.22 m). If the sheet thickness differs from 12 mm (0.47 inches), adjust the grooves in the CAD file accordingly.
![ds.PNG](./ds.PNG)
### Step 2: Get cad file in CNC machine
The CAD file must be converted into a CNC machine file format to allow the machine to operate efficiently.
![nknkj.PNG](./nknkj.PNG)
### Step 3: Buff the edges
### Instructions for Edge Polishing
Buff the edges to achieve a cleaner finish.
![maxresdefault.jpg](./maxresdefault.jpg)
### Step 4: Assemble the product
Assemble the product according to the instructions provided in the following document.
![mll.PNG](./mll.PNG)
## Resources
### Design Software
- CAD software (e.g., [AutoCAD](https://www.autodesk.com), [Fusion 360](https://www.autodesk.com)) for adjusting groove dimensions based on sheet thickness[1]
### CNC Machining Tools
- CAM software (e.g., [Mach3](https://www.machsupport.com), [Vectric](https://www.vectric.com)) to convert CAD files to machine-readable formats[1]
- Industrial CNC machine for precise sheet cutting[1]
### Edge Polishing Tools
- Handheld edge buffer or rotary tool (e.g., [Dremel](https://www.dremel.com)) with polishing attachments[1]
### Assembly Hardware
- Adjustable wrench for component tightening[1]
- Screwdriver set (Phillips and flathead)[1]
### Sheet Material
- 12 mm thick sheet (4 ft x 4 ft / 1.22 m x 1.22 m) of plywood or MDF[1]
## References
## Useful References
### Articles
- [The Wellbeing Toilet encourages correct pooping posture](https://www.designindaba.com/articles/creative-work/wellbeing-toilet-encourages-correct-pooping-posture)
- [From Idea to Triumph: The Squatty Potty Story](https://enterprisewired.com/from-idea-to-triumph-the-squatty-potty-story/)
- [Improve Your Flat-Edge Polishing Efficiency](https://www.parkindustries.com/blog/high-production-polishing/)
### Books
- [CNC Beginner's Guide - CAD, CAM, and Machining](https://books.industrialpress.com/cnc-beginners-guide/)
### Papers
- [An ergonomic approach to public squatting-type toilet design](https://pubmed.ncbi.nlm.nih.gov/9763240/)
### YouTube
- [Introduction to the CNC universe CAD, CAM, GCODE](https://www.youtube.com/watch?v=3rCzx4_e_n8)
### Open-source Designs
- [CNC Cutting Design Free DXF Files & Vectors](https://3axis.co/free-vectors/CNC+Cutting+Design)
### CAD & CNC Resources
- [How To Convert An Image For CNC](https://www.scan2cad.com/blog/tips/how-to-convert-an-image-for-cnc/)
- [How to Prepare CAD Files for CNC Machining](https://www.scan2cad.com/blog/cad/cad-files-cnc-machining/)

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"resources": "### Design Software \n- CAD software (e.g., [AutoCAD](https://www.autodesk.com), [Fusion 360](https://www.autodesk.com)) for adjusting groove dimensions based on sheet thickness[1] \n\n### CNC Machining Tools \n- CAM software (e.g., [Mach3](https://www.machsupport.com), [Vectric](https://www.vectric.com)) to convert CAD files to machine-readable formats[1] \n- Industrial CNC machine for precise sheet cutting[1] \n\n### Edge Polishing Tools \n- Handheld edge buffer or rotary tool (e.g., [Dremel](https://www.dremel.com)) with polishing attachments[1] \n\n### Assembly Hardware \n- Adjustable wrench for component tightening[1] \n- Screwdriver set (Phillips and flathead)[1] \n\n### Sheet Material \n- 12 mm thick sheet (4 ft x 4 ft / 1.22 m x 1.22 m) of plywood or MDF[1]",
"references": "## Useful References\n\n### Articles\n- [The Wellbeing Toilet encourages correct pooping posture](https://www.designindaba.com/articles/creative-work/wellbeing-toilet-encourages-correct-pooping-posture) \n- [From Idea to Triumph: The Squatty Potty Story](https://enterprisewired.com/from-idea-to-triumph-the-squatty-potty-story/) \n- [Improve Your Flat-Edge Polishing Efficiency](https://www.parkindustries.com/blog/high-production-polishing/) \n\n### Books\n- [CNC Beginner's Guide - CAD, CAM, and Machining](https://books.industrialpress.com/cnc-beginners-guide/) \n\n### Papers\n- [An ergonomic approach to public squatting-type toilet design](https://pubmed.ncbi.nlm.nih.gov/9763240/) \n\n### YouTube\n- [Introduction to the CNC universe CAD, CAM, GCODE](https://www.youtube.com/watch?v=3rCzx4_e_n8) \n\n### Open-source Designs\n- [CNC Cutting Design Free DXF Files & Vectors](https://3axis.co/free-vectors/CNC+Cutting+Design) \n\n### CAD & CNC Resources\n- [How To Convert An Image For CNC](https://www.scan2cad.com/blog/tips/how-to-convert-an-image-for-cnc/) \n- [How to Prepare CAD Files for CNC Machining](https://www.scan2cad.com/blog/cad/cad-files-cnc-machining/)"
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---
title: Make a Squat Stool
slug: make-a-squat-stool
description: I am a flat-pack design utility that can be added to existing English toilets to improve posture. This improvement can enhance the body's internal structure and aid in alleviating various stomach-related issues, thereby improving the digestive system. It addresses the posture habits of the younger generation using toilets in a manner originally intended.
tags: ["mould","HDPE","compression","starterkit"]
category: Products
difficulty: Easy
time: < 1 hour
location: Delhi, India
---
import { Image } from 'astro:assets'
# Make a Squat Stool
<Image src={import('./feed_7_2.png')} alt="Make a Squat Stool" />
I am a flat-pack design utility that can be added to existing English toilets to improve posture. This improvement can enhance the body's internal structure and aid in alleviating various stomach-related issues, thereby improving the digestive system. It addresses the posture habits of the younger generation using toilets in a manner originally intended.
User Location: Delhi, India
## Steps
### Step 1: Take sheet of 12mm thickness
The sheet must have a thickness of 12 mm (0.47 inches) for the precise grooving composition, with dimensions of 4 ft x 4 ft (1.22 m x 1.22 m). If the sheet thickness differs from 12 mm (0.47 inches), adjust the grooves in the CAD file accordingly.
<Image src={import('./ds.PNG')} alt="ds.PNG" />
### Step 2: Get cad file in CNC machine
The CAD file must be converted into a CNC machine file format to allow the machine to operate efficiently.
<Image src={import('./nknkj.PNG')} alt="nknkj.PNG" />
### Step 3: Buff the edges
### Instructions for Edge Polishing
Buff the edges to achieve a cleaner finish.
<Image src={import('./maxresdefault.jpg')} alt="maxresdefault.jpg" />
### Step 4: Assemble the product
Assemble the product according to the instructions provided in the following document.
<Image src={import('./mll.PNG')} alt="mll.PNG" />

22
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@ -0,0 +1,22 @@
## Useful References
### Articles
- [The Wellbeing Toilet encourages correct pooping posture](https://www.designindaba.com/articles/creative-work/wellbeing-toilet-encourages-correct-pooping-posture)
- [From Idea to Triumph: The Squatty Potty Story](https://enterprisewired.com/from-idea-to-triumph-the-squatty-potty-story/)
- [Improve Your Flat-Edge Polishing Efficiency](https://www.parkindustries.com/blog/high-production-polishing/)
### Books
- [CNC Beginner's Guide - CAD, CAM, and Machining](https://books.industrialpress.com/cnc-beginners-guide/)
### Papers
- [An ergonomic approach to public squatting-type toilet design](https://pubmed.ncbi.nlm.nih.gov/9763240/)
### YouTube
- [Introduction to the CNC universe CAD, CAM, GCODE](https://www.youtube.com/watch?v=3rCzx4_e_n8)
### Open-source Designs
- [CNC Cutting Design Free DXF Files & Vectors](https://3axis.co/free-vectors/CNC+Cutting+Design)
### CAD & CNC Resources
- [How To Convert An Image For CNC](https://www.scan2cad.com/blog/tips/how-to-convert-an-image-for-cnc/)
- [How to Prepare CAD Files for CNC Machining](https://www.scan2cad.com/blog/cad/cad-files-cnc-machining/)

16
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@ -0,0 +1,16 @@
### Design Software
- CAD software (e.g., [AutoCAD](https://www.autodesk.com), [Fusion 360](https://www.autodesk.com)) for adjusting groove dimensions based on sheet thickness[1]
### CNC Machining Tools
- CAM software (e.g., [Mach3](https://www.machsupport.com), [Vectric](https://www.vectric.com)) to convert CAD files to machine-readable formats[1]
- Industrial CNC machine for precise sheet cutting[1]
### Edge Polishing Tools
- Handheld edge buffer or rotary tool (e.g., [Dremel](https://www.dremel.com)) with polishing attachments[1]
### Assembly Hardware
- Adjustable wrench for component tightening[1]
- Screwdriver set (Phillips and flathead)[1]
### Sheet Material
- 12 mm thick sheet (4 ft x 4 ft / 1.22 m x 1.22 m) of plywood or MDF[1]

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---
title: Make Alphabet Magnets from PLA Scraps
slug: make-alphabet-magnets-from-pla-scraps
description: In this tutorial, you will create alphabet magnets using PLA scraps from 3D prints. This procedure requires the use of an oven and will reach temperatures of 400°F (204°C), necessitating appropriate safety gear.
tags: ["melting","collection"]
category: uncategorized
difficulty: Easy
time: < 5 hours
keywords: 3D print recycling, alphabet magnets, PLA scraps, DIY alphabet magnets, oven safety for crafts, PLA melting tutorial, home crafts with magnets, sustainable crafting, DIY tools list, crafting with oven.
location: Conway, United States of America (the)
---
# Make Alphabet Magnets from PLA Scraps
![Make Alphabet Magnets from PLA Scraps](DSC_4381-185a7943e53.JPG)
In this tutorial, you will create alphabet magnets using PLA scraps from 3D prints. This procedure requires the use of an oven and will reach temperatures of 400°F (204°C), necessitating appropriate safety gear.
User Location: Conway, United States of America (the)
## Steps
### Step 1: Gather Supplies and Safety Equipment
### Required Materials
- Small PLA Scraps
- Clippers
- Safety Glasses
- Oven Mitts
- Silicon Mold capable of withstanding up to 450°F (232°C)
- Cookie Sheet
- Magnetic Tape
- Exacto Knife
- Sanding Paper
- An Oven
![DSC_4380-185a7921003.JPG](./DSC_4380-185a7921003.JPG)
![DSC_4372-185a7922899.JPG](./DSC_4372-185a7922899.JPG)
### Step 2: Filling the Mold
Before filling the mold, place it on the cookie sheet to prevent spills. Wear safety glasses and use clippers to break down the PLA scraps until they fit in the mold. Be cautious, as the scraps may become airborne when clipped. Aim to fill the mold entirely.
![DSC_4371-185a7925792.JPG](./DSC_4371-185a7925792.JPG)
### Step 3: Melt the PLA
When you have finished filling the mold with plastic, transfer the cookie sheet with the mold to the oven. Preheat the oven to 400°F (204°C) and allow the plastic to melt. Our process took approximately 30 minutes, though this may vary with different ovens. Carefully monitor the plastic during this time. Once melted, use oven mitts to remove the cookie sheet from the oven and place it on a heat-resistant surface, such as the stovetop or another oven mitt. Allow the cookie sheet to cool before proceeding to the next step.
![DSC_4373-185a7928e93.JPG](./DSC_4373-185a7928e93.JPG)
![DSC_4375-185a7929bba.JPG](./DSC_4375-185a7929bba.JPG)
![DSC_4376-185a792a8fa.JPG](./DSC_4376-185a792a8fa.JPG)
### Step 4: Repeat Steps 2 & 3
The mold may not be sufficiently filled. Add more scraps and place them in the mold, then melt again. Repeat this process until the mold is filled.
![DSC_4377-185a79356bf.JPG](./DSC_4377-185a79356bf.JPG)
### Step 5: Pop the Letters Out and Put the Magnets On
After the mold has fully cooled down, remove the letters from the mold. Use sandpaper to smooth the backs of the letters until they are flat enough for the magnets.
Once the backs are flat, unroll some magnetic tape and place the letters on the adhesive side of the tape. Use an Exacto knife to trim the magnetic tape.
![DSC_4379-185a7939424.JPG](./DSC_4379-185a7939424.JPG)
![DSC_4378-185a793a305.JPG](./DSC_4378-185a793a305.JPG)
## Resources
To create alphabet magnets from PLA scraps, gather these essential items:
### Tools
- Clippers
- Exacto Knife
- Sanding Paper
### Hardware
- Oven (capable of 400°F/204°C)
- Cookie Sheet
- Silicon Mold (heat-resistant up to 450°F/232°C)
### Safety Gear
- Safety Glasses
- Oven Mitts
### Consumables
- PLA Scraps
- Magnetic Tape
## References
## Articles
- https://community.preciousplastic.com/library/make-a-box-from-3d-printing-scraps
- https://3d4create.com/pla-recycling-tips-and-tricks/
- https://www.3devo.com/blog/pla-recycling-everything-you-need-to-know
## YouTube
- https://www.youtube.com/watch?v=AlsI1TZux0c
- https://www.youtube.com/watch?v=wJgoH2Or03s
- https://www.youtube.com/watch?v=1MndPjh5Sdw
## Tutorials
- https://www.blueistyleblog.com/diyalphabetmagnets/
- https://merrypad.com/2016/04/14/diy-clay-magnet-letters/
- https://modernquiltlove.wordpress.com/2009/07/28/alphabet-magnet-tutorial/
- https://www.hallmarkchannel.com/home-and-family/how-to/diy-clay-magnets
## Papers
- https://dr.lib.iastate.edu/bitstreams/fdcf4326-9d90-4bed-9c1e-524a99e361f2/download
- https://www.birmingham.ac.uk/news/2022/pilot-recycling-plant-for-rare-earth-magnets-launched
## OpenSource Designs
- https://digitalcommons.mtu.edu/cgi/viewcontent.cgi?article=3787&context=michigantech-p

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"text": "You will need: \nSmall PLA Scraps \n - Clippers \n - Safety Glasses \n - Oven Mitts \n - Silicon Mold that can withstand up to 450°F \n - Cookie sheet \n - Magnetic tape \n - Exacto knife \n - Sanding paper \n - An oven ",
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"text": "Before filling the mold, place it on the cookie sheet to prevent spills. Wear safety glasses and use clippers to break down the PLA scraps until they fit in the mold. Be cautious, as the scraps may become airborne when clipped. Aim to fill the mold entirely.",
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"text": "Before filling the mold, put the mold on the cookie sheet to avoid spilling the scraps. Put on the safety glasses and use the clippers to break down the PLA scraps enough so that they fit in the mold. The scraps can go flying when you clip them. Try to fill the mold completely. "
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"text": "When you have finished filling the mold with plastic, transfer the cookie sheet with the mold to the oven. Preheat the oven to 400°F (204°C) and allow the plastic to melt. Our process took approximately 30 minutes, though this may vary with different ovens. Carefully monitor the plastic during this time. Once melted, use oven mitts to remove the cookie sheet from the oven and place it on a heat-resistant surface, such as the stovetop or another oven mitt. Allow the cookie sheet to cool before proceeding to the next step."
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"text": "The mold may not be filled up enough, so clip some more scraps, put it in, and ugh so clip some more scraps and put it in the mold and melt again. Repeat till the mold is filled.",
"title": "Repeat Steps 2 & 3",
"text": "The mold may not be sufficiently filled. Add more scraps and place them in the mold, then melt again. Repeat this process until the mold is filled.",
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"text": "After the mold has fully cooled down, remove the letters from the mold. Use sandpaper to smooth the backs of the letters until they are flat enough for the magnets.\n\nOnce the backs are flat, unroll some magnetic tape and place the letters on the adhesive side of the tape. Use an Exacto knife to trim the magnetic tape.",
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"text": "After the mold has fully cooled down, pop the letters out of the mold. Get the sandpaper and sand down the backs of the letters to make them flat enough for the magnets. \n\nWhen the backs are flat, roll out some magnetic tape and lay the letters on the sticky side of the tape. Use the Exacto knife to cut the magnetic tape off. "
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"content": "In this tutorial, you will create alphabet magnets using PLA scraps from 3D prints. This procedure requires the use of an oven and will reach temperatures of 400°F (204°C), necessitating appropriate safety gear.\n\n\nUser Location: Conway, United States of America (the)\n\n### Required Materials\n\n- Small PLA Scraps\n- Clippers\n- Safety Glasses\n- Oven Mitts\n- Silicon Mold capable of withstanding up to 450°F (232°C)\n- Cookie Sheet\n- Magnetic Tape\n- Exacto Knife\n- Sanding Paper\n- An Oven\n\nBefore filling the mold, place it on the cookie sheet to prevent spills. Wear safety glasses and use clippers to break down the PLA scraps until they fit in the mold. Be cautious, as the scraps may become airborne when clipped. Aim to fill the mold entirely.\n\nWhen you have finished filling the mold with plastic, transfer the cookie sheet with the mold to the oven. Preheat the oven to 400°F (204°C) and allow the plastic to melt. Our process took approximately 30 minutes, though this may vary with different ovens. Carefully monitor the plastic during this time. Once melted, use oven mitts to remove the cookie sheet from the oven and place it on a heat-resistant surface, such as the stovetop or another oven mitt. Allow the cookie sheet to cool before proceeding to the next step.\n\nThe mold may not be sufficiently filled. Add more scraps and place them in the mold, then melt again. Repeat this process until the mold is filled.\n\nAfter the mold has fully cooled down, remove the letters from the mold. Use sandpaper to smooth the backs of the letters until they are flat enough for the magnets.\n\nOnce the backs are flat, unroll some magnetic tape and place the letters on the adhesive side of the tape. Use an Exacto knife to trim the magnetic tape.",
"keywords": "3D print recycling, alphabet magnets, PLA scraps, DIY alphabet magnets, oven safety for crafts, PLA melting tutorial, home crafts with magnets, sustainable crafting, DIY tools list, crafting with oven.",
"resources": "To create alphabet magnets from PLA scraps, gather these essential items:\n\n### Tools\n- Clippers\n- Exacto Knife\n- Sanding Paper\n\n### Hardware\n- Oven (capable of 400°F/204°C)\n- Cookie Sheet\n- Silicon Mold (heat-resistant up to 450°F/232°C)\n\n### Safety Gear\n- Safety Glasses\n- Oven Mitts\n\n### Consumables\n- PLA Scraps\n- Magnetic Tape",
"references": "## Articles\n- https://community.preciousplastic.com/library/make-a-box-from-3d-printing-scraps \n- https://3d4create.com/pla-recycling-tips-and-tricks/ \n- https://www.3devo.com/blog/pla-recycling-everything-you-need-to-know \n\n## YouTube \n- https://www.youtube.com/watch?v=AlsI1TZux0c \n- https://www.youtube.com/watch?v=wJgoH2Or03s \n- https://www.youtube.com/watch?v=1MndPjh5Sdw \n\n## Tutorials \n- https://www.blueistyleblog.com/diyalphabetmagnets/ \n- https://merrypad.com/2016/04/14/diy-clay-magnet-letters/ \n- https://modernquiltlove.wordpress.com/2009/07/28/alphabet-magnet-tutorial/ \n- https://www.hallmarkchannel.com/home-and-family/how-to/diy-clay-magnets \n\n## Papers \n- https://dr.lib.iastate.edu/bitstreams/fdcf4326-9d90-4bed-9c1e-524a99e361f2/download \n- https://www.birmingham.ac.uk/news/2022/pilot-recycling-plant-for-rare-earth-magnets-launched \n\n## OpenSource Designs \n- https://digitalcommons.mtu.edu/cgi/viewcontent.cgi?article=3787&context=michigantech-p"
}

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---
title: Make Alphabet Magnets from PLA Scraps
slug: make-alphabet-magnets-from-pla-scraps
description: In this tutorial, you will create alphabet magnets using PLA scraps from 3D prints. This procedure requires the use of an oven and will reach temperatures of 400°F (204°C), necessitating appropriate safety gear.
tags: ["melting","collection"]
category: uncategorized
difficulty: Easy
time: < 5 hours
location: Conway, United States of America (the)
---
import { Image } from 'astro:assets'
# Make Alphabet Magnets from PLA Scraps
<Image src={import('./DSC_4381-185a7943e53.JPG')} alt="Make Alphabet Magnets from PLA Scraps" />
In this tutorial, you will create alphabet magnets using PLA scraps from 3D prints. This procedure requires the use of an oven and will reach temperatures of 400°F (204°C), necessitating appropriate safety gear.
User Location: Conway, United States of America (the)
## Steps
### Step 1: Gather Supplies and Safety Equipment
### Required Materials
- Small PLA Scraps
- Clippers
- Safety Glasses
- Oven Mitts
- Silicon Mold capable of withstanding up to 450°F (232°C)
- Cookie Sheet
- Magnetic Tape
- Exacto Knife
- Sanding Paper
- An Oven
<Image src={import('./DSC_4380-185a7921003.JPG')} alt="DSC_4380-185a7921003.JPG" />
<Image src={import('./DSC_4372-185a7922899.JPG')} alt="DSC_4372-185a7922899.JPG" />
### Step 2: Filling the Mold
Before filling the mold, place it on the cookie sheet to prevent spills. Wear safety glasses and use clippers to break down the PLA scraps until they fit in the mold. Be cautious, as the scraps may become airborne when clipped. Aim to fill the mold entirely.
<Image src={import('./DSC_4371-185a7925792.JPG')} alt="DSC_4371-185a7925792.JPG" />
### Step 3: Melt the PLA
When you have finished filling the mold with plastic, transfer the cookie sheet with the mold to the oven. Preheat the oven to 400°F (204°C) and allow the plastic to melt. Our process took approximately 30 minutes, though this may vary with different ovens. Carefully monitor the plastic during this time. Once melted, use oven mitts to remove the cookie sheet from the oven and place it on a heat-resistant surface, such as the stovetop or another oven mitt. Allow the cookie sheet to cool before proceeding to the next step.
<Image src={import('./DSC_4373-185a7928e93.JPG')} alt="DSC_4373-185a7928e93.JPG" />
<Image src={import('./DSC_4375-185a7929bba.JPG')} alt="DSC_4375-185a7929bba.JPG" />
<Image src={import('./DSC_4376-185a792a8fa.JPG')} alt="DSC_4376-185a792a8fa.JPG" />
### Step 4: Repeat Steps 2 & 3
The mold may not be sufficiently filled. Add more scraps and place them in the mold, then melt again. Repeat this process until the mold is filled.
<Image src={import('./DSC_4377-185a79356bf.JPG')} alt="DSC_4377-185a79356bf.JPG" />
### Step 5: Pop the Letters Out and Put the Magnets On
After the mold has fully cooled down, remove the letters from the mold. Use sandpaper to smooth the backs of the letters until they are flat enough for the magnets.
Once the backs are flat, unroll some magnetic tape and place the letters on the adhesive side of the tape. Use an Exacto knife to trim the magnetic tape.
<Image src={import('./DSC_4379-185a7939424.JPG')} alt="DSC_4379-185a7939424.JPG" />
<Image src={import('./DSC_4378-185a793a305.JPG')} alt="DSC_4378-185a793a305.JPG" />

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## Articles
- https://community.preciousplastic.com/library/make-a-box-from-3d-printing-scraps
- https://3d4create.com/pla-recycling-tips-and-tricks/
- https://www.3devo.com/blog/pla-recycling-everything-you-need-to-know
## YouTube
- https://www.youtube.com/watch?v=AlsI1TZux0c
- https://www.youtube.com/watch?v=wJgoH2Or03s
- https://www.youtube.com/watch?v=1MndPjh5Sdw
## Tutorials
- https://www.blueistyleblog.com/diyalphabetmagnets/
- https://merrypad.com/2016/04/14/diy-clay-magnet-letters/
- https://modernquiltlove.wordpress.com/2009/07/28/alphabet-magnet-tutorial/
- https://www.hallmarkchannel.com/home-and-family/how-to/diy-clay-magnets
## Papers
- https://dr.lib.iastate.edu/bitstreams/fdcf4326-9d90-4bed-9c1e-524a99e361f2/download
- https://www.birmingham.ac.uk/news/2022/pilot-recycling-plant-for-rare-earth-magnets-launched
## OpenSource Designs
- https://digitalcommons.mtu.edu/cgi/viewcontent.cgi?article=3787&context=michigantech-p

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To create alphabet magnets from PLA scraps, gather these essential items:
### Tools
- Clippers
- Exacto Knife
- Sanding Paper
### Hardware
- Oven (capable of 400°F/204°C)
- Cookie Sheet
- Silicon Mold (heat-resistant up to 450°F/232°C)
### Safety Gear
- Safety Glasses
- Oven Mitts
### Consumables
- PLA Scraps
- Magnetic Tape

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---
title: Make an under glass coaster
slug: make-an-under-glass-coaster
description: This tutorial describes the process of creating an attractive under-glass coaster from an HDPE sheet (0.79 inches).
tags: ["sheetpress","HDPE","product"]
category: Products
difficulty: Easy
time: < 5 hours
keywords: HDPE coasters, DIY under-glass coaster, creating coasters from HDPE sheet, coaster tutorial, lathe machining coasters, making attractive coasters, polishing coasters, crafting coasters Brussels, DIY coaster project, HDPE sheet crafts
location: Brussels, Belgium
---
# Make an under glass coaster
![Make an under glass coaster](A59E05F0-C417-4DEF-B382-64E99D334F1A-7302341C-FCF1-4FA6-832A-B2D7EDAB8602.jpg)
This tutorial describes the process of creating an attractive under-glass coaster from an HDPE sheet (0.79 inches).
User Location: Brussels, Belgium
## Steps
### Step 1: Cut the squares
Start by cutting perfect equal squares 4 inches (10 cm) apart. The more precise they are, the more aesthetically pleasing your coasters will be.
Ensure you have a plastic sheet of sufficient thickness to hollow out the circle for the base of the glass. You need approximately 0.19 inches (5 mm), so use a sheet at least 0.39 inches (1 cm) thick.
![IMG_3293.jpg](./IMG_3293.jpg)
![IMG_3298.jpg](./IMG_3298.jpg)
### Step 2: Hollow the circle (1)
Now that you have your squares, you require a lathe machine to create hollow circles.
Securely position your square in the clamping elements and make an initial hole in the center, 0.2 inches (5 mm) deep.
![IMG_3357.jpg](./IMG_3357.jpg)
![IMG_3358.jpg](./IMG_3358.jpg)
![IMG_3359.jpg](./IMG_3359.jpg)
### Step 3: Hollow the circle (2)
Now that you have your center hole, proceed to complete the circle.
Ensure you stop digging when there is approximately 0.2 inches (5 mm) of edge remaining on each side.
![IMG_3364.jpg](./IMG_3364.jpg)
![IMG_3367.jpg](./IMG_3367.jpg)
### Step 4: smooth it out
Using a polishing machine, round the four corners and smooth the surfaces as needed.
Additionally, round the edge of the hollow circle.
![IMG_3371.jpg](./IMG_3371.jpg)
![IMG_3375.jpg](./IMG_3375.jpg)
![IMG_3379.jpg](./IMG_3379.jpg)
### Step 5: Final result
Now you can enjoy your beverage on a splendid coaster.
![A59E05F0-C417-4DEF-B382-64E99D334F1A-7302341C-FCF1-4FA6-832A-B2D7EDAB8602.jpg](./A59E05F0-C417-4DEF-B382-64E99D334F1A-7302341C-FCF1-4FA6-832A-B2D7EDAB8602.jpg)
![384470AB-33CF-403D-9F53-607A9313C54D-3D675F4E-AECC-4B3E-B9ED-473FB0F29DC8.jpg](./384470AB-33CF-403D-9F53-607A9313C54D-3D675F4E-AECC-4B3E-B9ED-473FB0F29DC8.jpg)
![905A90A7-8804-4E78-AF10-A8CDEB32A96D-F24A14D9-7E3A-467F-81A8-6215262871A8.JPG](./905A90A7-8804-4E78-AF10-A8CDEB32A96D-F24A14D9-7E3A-467F-81A8-6215262871A8.JPG)
## Resources
### Tools & Machinery
- Lathe machine (for hollow circle creation)
- Polishing machine (corner rounding & surface smoothing)
- Drill press with 5mm bit (initial center hole)
- Clamping elements (secure workpiece during machining)
### Materials
- HDPE plastic sheet (minimum 1cm thickness)
### Brussels Suppliers
- [HDPE sheets](https://www.plasticsheets.be)
- [Workshop tools](https://www.techniekwinkel-brussel.be)
- [Machining services](https://www.makerspacebrussels.be)
## References
## Useful References
### Articles
- [How to Make Craft Resin Coasters (a Step by Step Tutorial)](https://thathomebirdlife.com/diy-make-craft-resin-coasters-step-by-step-tutorial/)
- [Machining High Density Polyethylene (HDPE): A Plastics Guide](https://aipprecision.com/machining-hdpe-plastics-guide/)
- [Plastic Smithing: How to Make Your Own HDPE Plastic Anything](https://www.instructables.com/HomemadePlastic/)
- [High Impact Art: Practical Smashed Glass Coaster](https://softsolder.com/2022/07/12/high-impact-art-practical-smashed-glass-coaster/)
### YouTube
- [How to Stitch Plastic Canvas Coasters Pattern #1 (Plastic ... - YouTube](https://www.youtube.com/watch?v=9rfm4cikHVU)
- [Machining Aluminum Isogrid Drink Coasters](https://www.youtube.com/watch?v=-XxDSFjIRa0)
- [How To Make Simple Scrap Wood Drink Coasters - YouTube](https://www.youtube.com/watch?v=JzhX9cB4v1Y)
- [Beginners' Guide to Melting HDPE - How to Make a Recycled Plastic ...](https://www.youtube.com/watch?v=-igxhoGEQFU)
- [Aqua ripple resin coaster tutorial - YouTube](https://www.youtube.com/watch?v=3unNplxiQmQ)
- [HDPE Epoxy Resin Mold. Re-usable plastic resin mold ... - YouTube](https://www.youtube.com/watch?v=2lpxj7_VP9M)
- [How To Make A Reusable HDPE Epoxy Resin Table Mold - YouTube](https://www.youtube.com/watch?v=J_0ekhH4UwU)
### Open Source Designs
- [100% Recycled Plastic Drink Coaster Hand Crafted - Recycledin](https://recycledin.store/products/coaster)
- [Wood and Resin Coaster Mold and Pour - YouTube](https://www.youtube.com/watch?v=ESsnpmxzH84)

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"content": "This tutorial describes the process of creating an attractive under-glass coaster from an HDPE sheet (0.79 inches).\n\n\nUser Location: Brussels, Belgium\n\nStart by cutting perfect equal squares 4 inches (10 cm) apart. The more precise they are, the more aesthetically pleasing your coasters will be.\n\nEnsure you have a plastic sheet of sufficient thickness to hollow out the circle for the base of the glass. You need approximately 0.19 inches (5 mm), so use a sheet at least 0.39 inches (1 cm) thick.\n\nNow that you have your squares, you require a lathe machine to create hollow circles.\n\nSecurely position your square in the clamping elements and make an initial hole in the center, 0.2 inches (5 mm) deep.\n\nNow that you have your center hole, proceed to complete the circle.\n\nEnsure you stop digging when there is approximately 0.2 inches (5 mm) of edge remaining on each side.\n\nUsing a polishing machine, round the four corners and smooth the surfaces as needed.\n\nAdditionally, round the edge of the hollow circle.\n\nNow you can enjoy your beverage on a splendid coaster.",
"keywords": "HDPE coasters, DIY under-glass coaster, creating coasters from HDPE sheet, coaster tutorial, lathe machining coasters, making attractive coasters, polishing coasters, crafting coasters Brussels, DIY coaster project, HDPE sheet crafts",
"resources": "### Tools & Machinery\n- Lathe machine (for hollow circle creation)\n- Polishing machine (corner rounding & surface smoothing)\n- Drill press with 5mm bit (initial center hole)\n- Clamping elements (secure workpiece during machining)\n\n### Materials\n- HDPE plastic sheet (minimum 1cm thickness)\n\n### Brussels Suppliers\n- [HDPE sheets](https://www.plasticsheets.be)\n- [Workshop tools](https://www.techniekwinkel-brussel.be)\n- [Machining services](https://www.makerspacebrussels.be)",
"references": "## Useful References\n\n### Articles\n- [How to Make Craft Resin Coasters (a Step by Step Tutorial)](https://thathomebirdlife.com/diy-make-craft-resin-coasters-step-by-step-tutorial/) \n- [Machining High Density Polyethylene (HDPE): A Plastics Guide](https://aipprecision.com/machining-hdpe-plastics-guide/) \n- [Plastic Smithing: How to Make Your Own HDPE Plastic Anything](https://www.instructables.com/HomemadePlastic/) \n- [High Impact Art: Practical Smashed Glass Coaster](https://softsolder.com/2022/07/12/high-impact-art-practical-smashed-glass-coaster/) \n\n### YouTube\n- [How to Stitch Plastic Canvas Coasters Pattern #1 (Plastic ... - YouTube](https://www.youtube.com/watch?v=9rfm4cikHVU) \n- [Machining Aluminum Isogrid Drink Coasters](https://www.youtube.com/watch?v=-XxDSFjIRa0) \n- [How To Make Simple Scrap Wood Drink Coasters - YouTube](https://www.youtube.com/watch?v=JzhX9cB4v1Y) \n- [Beginners' Guide to Melting HDPE - How to Make a Recycled Plastic ...](https://www.youtube.com/watch?v=-igxhoGEQFU) \n- [Aqua ripple resin coaster tutorial - YouTube](https://www.youtube.com/watch?v=3unNplxiQmQ) \n- [HDPE Epoxy Resin Mold. Re-usable plastic resin mold ... - YouTube](https://www.youtube.com/watch?v=2lpxj7_VP9M) \n- [How To Make A Reusable HDPE Epoxy Resin Table Mold - YouTube](https://www.youtube.com/watch?v=J_0ekhH4UwU) \n\n### Open Source Designs\n- [100% Recycled Plastic Drink Coaster Hand Crafted - Recycledin](https://recycledin.store/products/coaster) \n- [Wood and Resin Coaster Mold and Pour - YouTube](https://www.youtube.com/watch?v=ESsnpmxzH84)"
}

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---
title: Make an under glass coaster
slug: make-an-under-glass-coaster
description: This tutorial describes the process of creating an attractive under-glass coaster from an HDPE sheet (0.79 inches).
tags: ["sheetpress","HDPE","product"]
category: Products
difficulty: Easy
time: < 5 hours
location: Brussels, Belgium
---
import { Image } from 'astro:assets'
# Make an under glass coaster
<Image src={import('./A59E05F0-C417-4DEF-B382-64E99D334F1A-7302341C-FCF1-4FA6-832A-B2D7EDAB8602.jpg')} alt="Make an under glass coaster" />
This tutorial describes the process of creating an attractive under-glass coaster from an HDPE sheet (0.79 inches).
User Location: Brussels, Belgium
## Steps
### Step 1: Cut the squares
Start by cutting perfect equal squares 4 inches (10 cm) apart. The more precise they are, the more aesthetically pleasing your coasters will be.
Ensure you have a plastic sheet of sufficient thickness to hollow out the circle for the base of the glass. You need approximately 0.19 inches (5 mm), so use a sheet at least 0.39 inches (1 cm) thick.
<Image src={import('./IMG_3293.jpg')} alt="IMG_3293.jpg" />
<Image src={import('./IMG_3298.jpg')} alt="IMG_3298.jpg" />
### Step 2: Hollow the circle (1)
Now that you have your squares, you require a lathe machine to create hollow circles.
Securely position your square in the clamping elements and make an initial hole in the center, 0.2 inches (5 mm) deep.
<Image src={import('./IMG_3357.jpg')} alt="IMG_3357.jpg" />
<Image src={import('./IMG_3358.jpg')} alt="IMG_3358.jpg" />
<Image src={import('./IMG_3359.jpg')} alt="IMG_3359.jpg" />
### Step 3: Hollow the circle (2)
Now that you have your center hole, proceed to complete the circle.
Ensure you stop digging when there is approximately 0.2 inches (5 mm) of edge remaining on each side.
<Image src={import('./IMG_3364.jpg')} alt="IMG_3364.jpg" />
<Image src={import('./IMG_3367.jpg')} alt="IMG_3367.jpg" />
### Step 4: smooth it out
Using a polishing machine, round the four corners and smooth the surfaces as needed.
Additionally, round the edge of the hollow circle.
<Image src={import('./IMG_3371.jpg')} alt="IMG_3371.jpg" />
<Image src={import('./IMG_3375.jpg')} alt="IMG_3375.jpg" />
<Image src={import('./IMG_3379.jpg')} alt="IMG_3379.jpg" />
### Step 5: Final result
Now you can enjoy your beverage on a splendid coaster.
<Image src={import('./A59E05F0-C417-4DEF-B382-64E99D334F1A-7302341C-FCF1-4FA6-832A-B2D7EDAB8602.jpg')} alt="A59E05F0-C417-4DEF-B382-64E99D334F1A-7302341C-FCF1-4FA6-832A-B2D7EDAB8602.jpg" />
<Image src={import('./384470AB-33CF-403D-9F53-607A9313C54D-3D675F4E-AECC-4B3E-B9ED-473FB0F29DC8.jpg')} alt="384470AB-33CF-403D-9F53-607A9313C54D-3D675F4E-AECC-4B3E-B9ED-473FB0F29DC8.jpg" />
<Image src={import('./905A90A7-8804-4E78-AF10-A8CDEB32A96D-F24A14D9-7E3A-467F-81A8-6215262871A8.JPG')} alt="905A90A7-8804-4E78-AF10-A8CDEB32A96D-F24A14D9-7E3A-467F-81A8-6215262871A8.JPG" />

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## Useful References
### Articles
- [How to Make Craft Resin Coasters (a Step by Step Tutorial)](https://thathomebirdlife.com/diy-make-craft-resin-coasters-step-by-step-tutorial/)
- [Machining High Density Polyethylene (HDPE): A Plastics Guide](https://aipprecision.com/machining-hdpe-plastics-guide/)
- [Plastic Smithing: How to Make Your Own HDPE Plastic Anything](https://www.instructables.com/HomemadePlastic/)
- [High Impact Art: Practical Smashed Glass Coaster](https://softsolder.com/2022/07/12/high-impact-art-practical-smashed-glass-coaster/)
### YouTube
- [How to Stitch Plastic Canvas Coasters Pattern #1 (Plastic ... - YouTube](https://www.youtube.com/watch?v=9rfm4cikHVU)
- [Machining Aluminum Isogrid Drink Coasters](https://www.youtube.com/watch?v=-XxDSFjIRa0)
- [How To Make Simple Scrap Wood Drink Coasters - YouTube](https://www.youtube.com/watch?v=JzhX9cB4v1Y)
- [Beginners' Guide to Melting HDPE - How to Make a Recycled Plastic ...](https://www.youtube.com/watch?v=-igxhoGEQFU)
- [Aqua ripple resin coaster tutorial - YouTube](https://www.youtube.com/watch?v=3unNplxiQmQ)
- [HDPE Epoxy Resin Mold. Re-usable plastic resin mold ... - YouTube](https://www.youtube.com/watch?v=2lpxj7_VP9M)
- [How To Make A Reusable HDPE Epoxy Resin Table Mold - YouTube](https://www.youtube.com/watch?v=J_0ekhH4UwU)
### Open Source Designs
- [100% Recycled Plastic Drink Coaster Hand Crafted - Recycledin](https://recycledin.store/products/coaster)
- [Wood and Resin Coaster Mold and Pour - YouTube](https://www.youtube.com/watch?v=ESsnpmxzH84)

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### Tools & Machinery
- Lathe machine (for hollow circle creation)
- Polishing machine (corner rounding & surface smoothing)
- Drill press with 5mm bit (initial center hole)
- Clamping elements (secure workpiece during machining)
### Materials
- HDPE plastic sheet (minimum 1cm thickness)
### Brussels Suppliers
- [HDPE sheets](https://www.plasticsheets.be)
- [Workshop tools](https://www.techniekwinkel-brussel.be)
- [Machining services](https://www.makerspacebrussels.be)

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---
title: Make christmas ornaments from upcycled bottle caps
slug: make-christmas-ornaments-from-upcycled-bottle-caps
description: Transform your plastic waste into charming Christmas ornaments suitable for decoration or gift embellishments.
Required materials:
- Bottle caps
- A flat-surface panini press
- Silicone gloves
- Baking paper
- Eye protection
- Respirator mask
- A fret saw (manual or electrical)
- Sharp knife or razor blade
- Cookie cutters or paper stencil
tags: ["melting","PP","HDPE","product"]
category: Products
difficulty: Easy
time: < 5 hours
keywords: plastic waste recycling, Christmas ornaments, DIY holiday crafts, bottle cap crafts, eco-friendly decorations, upcycled holiday decorations, homemade Christmas gifts, sustainable crafting, plastic bottle cap recycling, zero waste Christmas
location: Luneburg, Germany
---
# Make christmas ornaments from upcycled bottle caps
![Make christmas ornaments from upcycled bottle caps](InMocean-xmas-ornaments-a.jpg)
Transform your plastic waste into charming Christmas ornaments suitable for decoration or gift embellishments.
Required materials:
- Bottle caps
- A flat-surface panini press
- Silicone gloves
- Baking paper
- Eye protection
- Respirator mask
- A fret saw (manual or electrical)
- Sharp knife or razor blade
- Cookie cutters or paper stencil
User Location: Luneburg, Germany
## Steps
### Step 1: Sort your bottle caps
First, sort your bottle caps to ensure uniformity in the type of plastic used. You may utilize either HDPE or PP bottle caps. The recycling category is typically marked inside the cap: number 2 for HDPE and number 5 for PP.
If labels are absent, identify the material by squeezing the caps slightly. HDPE caps tend to be somewhat flexible, while PP caps are more rigid. Caps from milk jugs are commonly HDPE, whereas soda bottle caps might be PP. When uncertain, discard the cap to prevent batch contamination.
![InMocean-xmas-ornaments-2a.jpg](./InMocean-xmas-ornaments-2a.jpg)
### Step 2: Wash your bottle caps
Once sorted, wash the caps you intend to use. You may either soak them in a sink and clean them manually with a brush, or for larger quantities, place them in a clothes bag and use a short washing cycle in the washing machine. Ensure they are completely dry before proceeding to the next step.
Consider the colors desired for your ornaments. Red and white can serve as base colors, with additional highlights of another color to enhance the visual appeal. The choice of colors is entirely at your discretion and dependent on availability.
![InMocean-xmas-ornaments-3a.jpg](./InMocean-xmas-ornaments-3a.jpg)
![InMocean-xmas-ornaments-4a.jpg](./InMocean-xmas-ornaments-4a.jpg)
### Step 3: First layer of bottle caps
Plug in your panini press and allow it to heat thoroughly. Ensure the device features a flat surface to produce a smooth plastic sheet suitable for ornaments. Once heated, set a baking sheet on the press. Teflon baking sheets are optimal due to their durability and resistance to tearing.
Position the bottle caps on the panini press. Orientation is irrelevant as they will melt uniformly. Cover the bottle caps with an additional baking sheet and securely close the panini press.
To aid the melting process, place a heavy object atop the panini press. Suitable items include bricks or heavy books, depending on availability.
![InMocean-xmas-ornaments-5a.jpg](./InMocean-xmas-ornaments-5a.jpg)
### Step 4: Second or third layer
Once your bottle caps are melted, you can add one or two more layers on top in the same manner as in Step 2. This depends on your desired ornament thickness. Aim for a thickness of 1/8 to 5/32 inches (3 to 4mm) for the plastic sheet. You will need to melt 2 to 4 layers of bottle caps, depending on the size of the caps.
![InMocean-xmas-ornaments-6a.jpg](./InMocean-xmas-ornaments-6a.jpg)
![InMocean-xmas-ornaments-7a.jpg](./InMocean-xmas-ornaments-7a.jpg)
### Step 5: Create a beautiful batik desig
Now you should have a layer of melted bottle caps. You may either use the sheet immediately or create a batik design. To do so, wear silicone gloves, roll the warm plastic into a cylindrical shape, and twist it. This step allows for creative expression. Pull the warm plastic to stretch it, fold it together, and twist it again until you achieve your desired design. If the plastic hardens during the process, reheat it to restore its moldable state.
At this stage, you have a lump of plastic that requires remelting to form a flat sheet.
![InMocean-xmas-ornaments-8a.jpg](./InMocean-xmas-ornaments-8a.jpg)
### Step 6: Make a flat sheet
Place the plastic piece inside the panini press and heat it. Once the plastic begins to soften, apply pressure to the panini press again. It may be helpful to sit on it carefully to avoid injury and move slightly to ensure the plastic spreads adequately.
Alternatively, remove the plastic from the press and use a rolling pin. However, keeping the plastic on the press generally yields better results as it remains in contact with the heat source.
![InMocean-xmas-ornaments-9a.jpg](./InMocean-xmas-ornaments-9a.jpg)
### Step 7: Let it cool down
Open the press periodically to check if you have reached the desired thickness of the sheet. Once it is satisfactory, switch off the press and allow the sheet to cool. Ensure that a heavy object is placed on top of the press; otherwise, the material may deform during cooling.
![InMocean-xmas-ornaments-10a.jpg](./InMocean-xmas-ornaments-10a.jpg)
### Step 8: Draw your ornaments onto sheet
Once your sheet has cooled down, it is time to exercise your creativity. Use a pen that writes on plastic to draw your ornaments on the plastic sheet. Cookie cutters can serve as templates, or you can craft your own stencils from paper.
When selecting a design, consider the cutting process; intricate or delicate designs may be more challenging to cut out. It might be wise to begin with a simple design and then progress to more complex creations.
![InMocean-xmas-ornaments-11a.jpg](./InMocean-xmas-ornaments-11a.jpg)
### Step 9: Cut out the ornaments
Now it is time to cut. For this step, you need a fretsaw. This can be either manual or electric, both are suitable. We used an electric one as it simplifies the process. However, a manual one is equally viable, requiring just a bit more patience. Move the saw along the lines drawn on the plastic sheet and voilà: you have your Christmas Ornament.
![InMocean-xmas-ornaments-12a.jpg](./InMocean-xmas-ornaments-12a.jpg)
![InMocean-xmas-ornaments-13a.jpg](./InMocean-xmas-ornaments-13a.jpg)
![InMocean-xmas-ornaments-13-2a.jpg](./InMocean-xmas-ornaments-13-2a.jpg)
### Step 10: Clean the edges
Use a sharp knife or razor blade to clean the edges of your ornament. This method is often more effective than using sandpaper and generates fewer small plastic pieces.
Remember to collect all the small pieces that are trimmed off during your crafting process, as these can be reused in your next project.
![InMocean-xmas-ornaments-14a.jpg](./InMocean-xmas-ornaments-14a.jpg)
### Step 11: Drill a hole and add a string
You are nearly prepared. Drill a small hole into the top of your ornament to accommodate a string. The hole's size should match the string's thickness.
Your ornaments are now ready. Well done on reducing waste produced during the Christmas season.
![InMocean-xmas-ornaments-15a.jpg](./InMocean-xmas-ornaments-15a.jpg)
![InMocean-xmas-ornaments-16a.jpg](./InMocean-xmas-ornaments-16a.jpg)
### Step 12: Gift the ornament to a friend
This step is optional. By gifting your handmade ornaments to friends or family, you convey that new purchases are unnecessary for decorating during the holiday season. Creating ornaments from bottle caps makes effective use of materials that might otherwise be discarded. You also craft an ornament with care.
Merry Christmas,
Maria & Nike from IN MOCEAN
[Website](https://in-mocean.org)
![InMocean-xmas-ornaments-17a.jpg](./InMocean-xmas-ornaments-17a.jpg)
![InMocean-xmas-ornaments-18.jpg](./InMocean-xmas-ornaments-18.jpg)
## Resources
To create Christmas ornaments from plastic bottle caps, you'll need specific tools and equipment. Below is the categorized list of required items based on the tutorial.
### Tools
- Fret saw (manual or electrical) [1]
- Sharp knife or razor blade [1]
- Cookie cutters or paper stencils [1]
- Clothes bag and washing machine (for cleaning caps) [1]
- Rolling pin (optional, for flattening sheets) [1]
### Safety Equipment
- Silicone gloves [1]
- Eye protection [1]
- Respirator mask [1]
### Hardware
- Flat-surface panini press [1]
- Baking paper (preferably Teflon) [1]
- Heavy objects (e.g., bricks, books for press weight) [1]
- Drill (for creating ornament holes) [1]
- String (for hanging ornaments) [1]
Source: [IN MOCEAN](https://in-mocean.org)
## References
## Articles
- [Bottle Cap Drink Coaster - Instructables](https://www.instructables.com/Bottle-Cap-Drink-Coaster/)
- [Upcycled DIY Christmas Ornaments - Ocean Blue Project](https://oceanblueproject.org/upcycled-diy-christmas-ornaments-for-a-green-christmas-this-year/)
- [Bottle Cap Decorations - Incredibusy](https://incredibusy.com/bottle-cap-decorations/)
- [Bottle Cap Crafts - Instructables](https://www.instructables.com/Bottle-Cap-Crafts/)
## Books
- [Ending Plastic Waste - CSIRO Publishing](https://www.publish.csiro.au/book/7923/)
## Papers
- [Upcycling Plastics to Reduce Greenhouse Gas Emissions - Journal of the American Chemical Society](https://chbe.illinois.edu/news/stories/plastic-upcycling-JACS-2022)
## YouTube
- [Christmas Ornament Makeover | Upcycling Old Baubles - YouTube](https://www.youtube.com/watch?v=MiwMSvDSxwc)
## Opensource Designs
- [40mm Bottle Cap by ElTorro5150 - Printables](https://www.printables.com/model/259286-40mm-bottle-cap)
- [Universal Bottle Opener - ENABL3D](https://enabl3d.me/tag/bottle-openers/)
- [Best 3D Printed Bottle Openers - All3DP](https://all3dp.com/2/best-3d-printed-bottle-opener-3d-print/)
- [Cool 3D Printer Designs - Format](https://www.format.com/magazine/resources/design/3d-printer-designs)

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---
title: Make christmas ornaments from upcycled bottle caps
slug: make-christmas-ornaments-from-upcycled-bottle-caps
description: Transform your plastic waste into charming Christmas ornaments suitable for decoration or gift embellishments.
Required materials:
- Bottle caps
- A flat-surface panini press
- Silicone gloves
- Baking paper
- Eye protection
- Respirator mask
- A fret saw (manual or electrical)
- Sharp knife or razor blade
- Cookie cutters or paper stencil
tags: ["melting","PP","HDPE","product"]
category: Products
difficulty: Easy
time: < 5 hours
location: Luneburg, Germany
---
import { Image } from 'astro:assets'
# Make christmas ornaments from upcycled bottle caps
<Image src={import('./InMocean-xmas-ornaments-a.jpg')} alt="Make christmas ornaments from upcycled bottle caps" />
Transform your plastic waste into charming Christmas ornaments suitable for decoration or gift embellishments.
Required materials:
- Bottle caps
- A flat-surface panini press
- Silicone gloves
- Baking paper
- Eye protection
- Respirator mask
- A fret saw (manual or electrical)
- Sharp knife or razor blade
- Cookie cutters or paper stencil
User Location: Luneburg, Germany
## Steps
### Step 1: Sort your bottle caps
First, sort your bottle caps to ensure uniformity in the type of plastic used. You may utilize either HDPE or PP bottle caps. The recycling category is typically marked inside the cap: number 2 for HDPE and number 5 for PP.
If labels are absent, identify the material by squeezing the caps slightly. HDPE caps tend to be somewhat flexible, while PP caps are more rigid. Caps from milk jugs are commonly HDPE, whereas soda bottle caps might be PP. When uncertain, discard the cap to prevent batch contamination.
<Image src={import('./InMocean-xmas-ornaments-2a.jpg')} alt="InMocean-xmas-ornaments-2a.jpg" />
### Step 2: Wash your bottle caps
Once sorted, wash the caps you intend to use. You may either soak them in a sink and clean them manually with a brush, or for larger quantities, place them in a clothes bag and use a short washing cycle in the washing machine. Ensure they are completely dry before proceeding to the next step.
Consider the colors desired for your ornaments. Red and white can serve as base colors, with additional highlights of another color to enhance the visual appeal. The choice of colors is entirely at your discretion and dependent on availability.
<Image src={import('./InMocean-xmas-ornaments-3a.jpg')} alt="InMocean-xmas-ornaments-3a.jpg" />
<Image src={import('./InMocean-xmas-ornaments-4a.jpg')} alt="InMocean-xmas-ornaments-4a.jpg" />
### Step 3: First layer of bottle caps
Plug in your panini press and allow it to heat thoroughly. Ensure the device features a flat surface to produce a smooth plastic sheet suitable for ornaments. Once heated, set a baking sheet on the press. Teflon baking sheets are optimal due to their durability and resistance to tearing.
Position the bottle caps on the panini press. Orientation is irrelevant as they will melt uniformly. Cover the bottle caps with an additional baking sheet and securely close the panini press.
To aid the melting process, place a heavy object atop the panini press. Suitable items include bricks or heavy books, depending on availability.
<Image src={import('./InMocean-xmas-ornaments-5a.jpg')} alt="InMocean-xmas-ornaments-5a.jpg" />
### Step 4: Second or third layer
Once your bottle caps are melted, you can add one or two more layers on top in the same manner as in Step 2. This depends on your desired ornament thickness. Aim for a thickness of 1/8 to 5/32 inches (3 to 4mm) for the plastic sheet. You will need to melt 2 to 4 layers of bottle caps, depending on the size of the caps.
<Image src={import('./InMocean-xmas-ornaments-6a.jpg')} alt="InMocean-xmas-ornaments-6a.jpg" />
<Image src={import('./InMocean-xmas-ornaments-7a.jpg')} alt="InMocean-xmas-ornaments-7a.jpg" />
### Step 5: Create a beautiful batik desig
Now you should have a layer of melted bottle caps. You may either use the sheet immediately or create a batik design. To do so, wear silicone gloves, roll the warm plastic into a cylindrical shape, and twist it. This step allows for creative expression. Pull the warm plastic to stretch it, fold it together, and twist it again until you achieve your desired design. If the plastic hardens during the process, reheat it to restore its moldable state.
At this stage, you have a lump of plastic that requires remelting to form a flat sheet.
<Image src={import('./InMocean-xmas-ornaments-8a.jpg')} alt="InMocean-xmas-ornaments-8a.jpg" />
### Step 6: Make a flat sheet
Place the plastic piece inside the panini press and heat it. Once the plastic begins to soften, apply pressure to the panini press again. It may be helpful to sit on it carefully to avoid injury and move slightly to ensure the plastic spreads adequately.
Alternatively, remove the plastic from the press and use a rolling pin. However, keeping the plastic on the press generally yields better results as it remains in contact with the heat source.
<Image src={import('./InMocean-xmas-ornaments-9a.jpg')} alt="InMocean-xmas-ornaments-9a.jpg" />
### Step 7: Let it cool down
Open the press periodically to check if you have reached the desired thickness of the sheet. Once it is satisfactory, switch off the press and allow the sheet to cool. Ensure that a heavy object is placed on top of the press; otherwise, the material may deform during cooling.
<Image src={import('./InMocean-xmas-ornaments-10a.jpg')} alt="InMocean-xmas-ornaments-10a.jpg" />
### Step 8: Draw your ornaments onto sheet
Once your sheet has cooled down, it is time to exercise your creativity. Use a pen that writes on plastic to draw your ornaments on the plastic sheet. Cookie cutters can serve as templates, or you can craft your own stencils from paper.
When selecting a design, consider the cutting process; intricate or delicate designs may be more challenging to cut out. It might be wise to begin with a simple design and then progress to more complex creations.
<Image src={import('./InMocean-xmas-ornaments-11a.jpg')} alt="InMocean-xmas-ornaments-11a.jpg" />
### Step 9: Cut out the ornaments
Now it is time to cut. For this step, you need a fretsaw. This can be either manual or electric, both are suitable. We used an electric one as it simplifies the process. However, a manual one is equally viable, requiring just a bit more patience. Move the saw along the lines drawn on the plastic sheet and voilà: you have your Christmas Ornament.
<Image src={import('./InMocean-xmas-ornaments-12a.jpg')} alt="InMocean-xmas-ornaments-12a.jpg" />
<Image src={import('./InMocean-xmas-ornaments-13a.jpg')} alt="InMocean-xmas-ornaments-13a.jpg" />
<Image src={import('./InMocean-xmas-ornaments-13-2a.jpg')} alt="InMocean-xmas-ornaments-13-2a.jpg" />
### Step 10: Clean the edges
Use a sharp knife or razor blade to clean the edges of your ornament. This method is often more effective than using sandpaper and generates fewer small plastic pieces.
Remember to collect all the small pieces that are trimmed off during your crafting process, as these can be reused in your next project.
<Image src={import('./InMocean-xmas-ornaments-14a.jpg')} alt="InMocean-xmas-ornaments-14a.jpg" />
### Step 11: Drill a hole and add a string
You are nearly prepared. Drill a small hole into the top of your ornament to accommodate a string. The hole's size should match the string's thickness.
Your ornaments are now ready. Well done on reducing waste produced during the Christmas season.
<Image src={import('./InMocean-xmas-ornaments-15a.jpg')} alt="InMocean-xmas-ornaments-15a.jpg" />
<Image src={import('./InMocean-xmas-ornaments-16a.jpg')} alt="InMocean-xmas-ornaments-16a.jpg" />
### Step 12: Gift the ornament to a friend
This step is optional. By gifting your handmade ornaments to friends or family, you convey that new purchases are unnecessary for decorating during the holiday season. Creating ornaments from bottle caps makes effective use of materials that might otherwise be discarded. You also craft an ornament with care.
Merry Christmas,
Maria & Nike from IN MOCEAN
[Website](https://in-mocean.org)
<Image src={import('./InMocean-xmas-ornaments-17a.jpg')} alt="InMocean-xmas-ornaments-17a.jpg" />
<Image src={import('./InMocean-xmas-ornaments-18.jpg')} alt="InMocean-xmas-ornaments-18.jpg" />

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## Articles
- [Bottle Cap Drink Coaster - Instructables](https://www.instructables.com/Bottle-Cap-Drink-Coaster/)
- [Upcycled DIY Christmas Ornaments - Ocean Blue Project](https://oceanblueproject.org/upcycled-diy-christmas-ornaments-for-a-green-christmas-this-year/)
- [Bottle Cap Decorations - Incredibusy](https://incredibusy.com/bottle-cap-decorations/)
- [Bottle Cap Crafts - Instructables](https://www.instructables.com/Bottle-Cap-Crafts/)
## Books
- [Ending Plastic Waste - CSIRO Publishing](https://www.publish.csiro.au/book/7923/)
## Papers
- [Upcycling Plastics to Reduce Greenhouse Gas Emissions - Journal of the American Chemical Society](https://chbe.illinois.edu/news/stories/plastic-upcycling-JACS-2022)
## YouTube
- [Christmas Ornament Makeover | Upcycling Old Baubles - YouTube](https://www.youtube.com/watch?v=MiwMSvDSxwc)
## Opensource Designs
- [40mm Bottle Cap by ElTorro5150 - Printables](https://www.printables.com/model/259286-40mm-bottle-cap)
- [Universal Bottle Opener - ENABL3D](https://enabl3d.me/tag/bottle-openers/)
- [Best 3D Printed Bottle Openers - All3DP](https://all3dp.com/2/best-3d-printed-bottle-opener-3d-print/)
- [Cool 3D Printer Designs - Format](https://www.format.com/magazine/resources/design/3d-printer-designs)

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To create Christmas ornaments from plastic bottle caps, you'll need specific tools and equipment. Below is the categorized list of required items based on the tutorial.
### Tools
- Fret saw (manual or electrical) [1]
- Sharp knife or razor blade [1]
- Cookie cutters or paper stencils [1]
- Clothes bag and washing machine (for cleaning caps) [1]
- Rolling pin (optional, for flattening sheets) [1]
### Safety Equipment
- Silicone gloves [1]
- Eye protection [1]
- Respirator mask [1]
### Hardware
- Flat-surface panini press [1]
- Baking paper (preferably Teflon) [1]
- Heavy objects (e.g., bricks, books for press weight) [1]
- Drill (for creating ornament holes) [1]
- String (for hanging ornaments) [1]
Source: [IN MOCEAN](https://in-mocean.org)

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---
title: Make great beam patterns!
slug: make-great-beam-patterns
description: Occasionally, inquiries arise regarding how to achieve appealing patterns in beams. Interestingly, no special technical methods are employed to accomplish this. The technique involves utilizing a basic steel pipe as a mold and allowing the extruder to perform its function. Here is a method you can attempt to achieve similar results.
tags: ["extrusion","HDPE","PP","LDPE"]
category: Guides
difficulty: Easy
time: < 1 hour
keywords: beam patterns, extruder technique, steel pipe mold, color mixing in extrusion, extruder material layering, PP and PE extrusion, plastic flow dynamics, mold cooling techniques, square tube patterns, circular beam patterns
location:
---
# Make great beam patterns!
![Make great beam patterns!](DSC_0675_copy.jpg)
Occasionally, inquiries arise regarding how to achieve appealing patterns in beams. Interestingly, no special technical methods are employed to accomplish this. The technique involves utilizing a basic steel pipe as a mold and allowing the extruder to perform its function. Here is a method you can attempt to achieve similar results.
## Steps
### Step 1: Prepare your blends carefully
To create patterns with distinct layers, a minimum of two colors is required. There is no noticeable difference when working with PP or PE for this purpose. Ensure that color mixes remain separate. In this instance, dark blue was combined with transparent flakes, serving as an effective filler. This results in a decreased requirement for dark blue to achieve the desired effect, as the color pigments are typically potent. For example, combining 2.2 lbs (1 kg) of transparent material with 2.2 lbs (1 kg) of dark blue yields a total of 4.4 lbs (2 kg) of dark blue without compromising color quality. The white used in this process is pure white.
![Screen Shot 2020-12-12 at 18.31.26.png](./Screen_Shot_2020-12-12_at_18.31.26.png)
### Step 2: Time to do the cooking!
Insert a few scoops into your extruder, activate the machine, and observe if the material is fully melted. Attach your cold mold and restart the machine. For the initial color, use approximately 3 scoops in total (subtracting any leftover already in the hopper). When the hopper is nearly empty, add 2 scoops of your second color. Continue this process, adjusting quantities, until the mold is filled. Allow it to cool slightly before removal. It has been suggested to cool the mold in water to prevent material from escaping, but this is typically unnecessary in this context.
![Schermafbeelding 2021-01-08 om 17.07.02.png](./Schermafbeelding_2021-01-08_om_17.07.02.png)
![Schermafbeelding 2021-01-08 om 17.07.31.png](./Schermafbeelding_2021-01-08_om_17.07.31.png)
### Step 3: Unboxing and see what came out
It is time to examine the outcome of the mixture. When you begin cutting the beam into smaller segments, you will notice an interesting change in the pattern. The most plausible explanation is as follows: The first color added adheres to the mold's wall or surface and cools slightly. The core remains fluid, allowing the second color to pass through. Continuously altering the input color will create multiple layers within your beam. Refer to the next step for further theoretical explanation.
![Screen Shot 2020-12-12 at 18.35.06.png](./Screen_Shot_2020-12-12_at_18.35.06.png)
![Screen Shot 2020-12-12 at 18.35.25.png](./Screen_Shot_2020-12-12_at_18.35.25.png)
![Screen Shot 2020-12-12 at 18.35.58.png](./Screen_Shot_2020-12-12_at_18.35.58.png)
### Step 4: Theory part 2 & proces video
Another important theory is that further into the mold, the plastic cools down, causing a buildup of pressure to facilitate the plastic flow. The farther from the inlet, the patterns become intriguing due to variations in temperature, flow, and pressure. This is particularly interesting with square tubes, as the corners cause the flow to slow. I assume a round tube will only produce circular patterns.
Watch the video to see the creation of a chessboard with these remarkable beams. Thank you for reading, and enjoy creating your patterns!
## Resources
### Hardware
- Basic steel pipe mold (used for shaping beams)
- Extruder machine (melts and processes plastic)
- Hopper (feeds material into the extruder)
### Materials
- Minimum two colored plastics (e.g., dark blue and white)
- Transparent flakes (act as filler for color dilution)
- Pure white plastic (no additives for brighter results)
### Tools
- Scoops (for adding measured quantities of plastic)
- Water (optional cooling aid for mold stabilization)
### Process-Specific Items
- Adjustable color ratios (e.g., 1:1 mix of dark blue and transparent flakes)
- Temperature-controlled environment (for cooling layers effectively)
### Supplementary
- Chessboard pattern example (referenced video demonstration)
## References
## Articles
- https://community.preciousplastic.com/library/make-a-mould-to-extrude-beams
- https://onearmy.github.io/academy/create/design
- https://community.preciousplastic.com/library/extrude-different-textures
## Youtube
- https://www.youtube.com/watch?v=6bb2qIUMVs8
- https://www.youtube.com/watch?v=t8PpQtInVhE
## Opensource Designs
- https://www.instructables.com/Recycled-Plastic-Chessboard-With-Unique-Patterns/
- https://www.instructables.com/Automated-Chessboard/
## Papers
- https://research.tue.nl/files/72619856/benelearn_2017.pdf

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"text": "Insert a few scoops in your extruder, turn the machine on and see if it comes out fully melted. Install your (cold) mold and turn on the machine again. For the first color I would go for 3 scoops in total ( minus the leftover already in the hopper). When the hopper is almost empty, toss in 2 scoops of your second color. Repeat this step while playing with the quantities until the mold is full. Time to remove to cool down a bit. I noticed the advice of cooling the mold in water to prevent plastic of running out, but that hardly happens in here so I never do that. ",
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"text": "Time to check out what the mix did! :-) When you start cutting the beam into little bits you will see an interesting changing of the pattern and my best explanation would be the following: The first color inserted sticks to the wall/surface of the mold and cools down a little. The core stays fluid and gains acces for the second color to pass trough. changing the input color again and again will create multiple layers in your beam. See next step for theory part 2 :-)",
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"text": "Another important theory is that... further in the mold, the plastic will be less hot so pressure is being build up more in order to let the plastic flow. The further away from the inlet, the patterns start to get very interesting and that's all created by differences in temperature flows and pressure. Especially with the square tube is this super interesting because of the corners where the flow will slow down more. I assume round tube will only create circle patterns. \n\nCheck out the video to see the making of a Chessboard with these amazing beams. Thank you for reading and enjoy your pattern creating!",
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"content": "Occasionally, inquiries arise regarding how to achieve appealing patterns in beams. Interestingly, no special technical methods are employed to accomplish this. The technique involves utilizing a basic steel pipe as a mold and allowing the extruder to perform its function. Here is a method you can attempt to achieve similar results.\n\nTo create patterns with distinct layers, a minimum of two colors is required. There is no noticeable difference when working with PP or PE for this purpose. Ensure that color mixes remain separate. In this instance, dark blue was combined with transparent flakes, serving as an effective filler. This results in a decreased requirement for dark blue to achieve the desired effect, as the color pigments are typically potent. For example, combining 2.2 lbs (1 kg) of transparent material with 2.2 lbs (1 kg) of dark blue yields a total of 4.4 lbs (2 kg) of dark blue without compromising color quality. The white used in this process is pure white.\n\nInsert a few scoops into your extruder, activate the machine, and observe if the material is fully melted. Attach your cold mold and restart the machine. For the initial color, use approximately 3 scoops in total (subtracting any leftover already in the hopper). When the hopper is nearly empty, add 2 scoops of your second color. Continue this process, adjusting quantities, until the mold is filled. Allow it to cool slightly before removal. It has been suggested to cool the mold in water to prevent material from escaping, but this is typically unnecessary in this context.\n\nIt is time to examine the outcome of the mixture. When you begin cutting the beam into smaller segments, you will notice an interesting change in the pattern. The most plausible explanation is as follows: The first color added adheres to the mold's wall or surface and cools slightly. The core remains fluid, allowing the second color to pass through. Continuously altering the input color will create multiple layers within your beam. Refer to the next step for further theoretical explanation.\n\nAnother important theory is that further into the mold, the plastic cools down, causing a buildup of pressure to facilitate the plastic flow. The farther from the inlet, the patterns become intriguing due to variations in temperature, flow, and pressure. This is particularly interesting with square tubes, as the corners cause the flow to slow. I assume a round tube will only produce circular patterns.\n\nWatch the video to see the creation of a chessboard with these remarkable beams. Thank you for reading, and enjoy creating your patterns!",
"keywords": "beam patterns, extruder technique, steel pipe mold, color mixing in extrusion, extruder material layering, PP and PE extrusion, plastic flow dynamics, mold cooling techniques, square tube patterns, circular beam patterns",
"resources": "### Hardware \n- Basic steel pipe mold (used for shaping beams) \n- Extruder machine (melts and processes plastic) \n- Hopper (feeds material into the extruder) \n\n### Materials \n- Minimum two colored plastics (e.g., dark blue and white) \n- Transparent flakes (act as filler for color dilution) \n- Pure white plastic (no additives for brighter results) \n\n### Tools \n- Scoops (for adding measured quantities of plastic) \n- Water (optional cooling aid for mold stabilization) \n\n### Process-Specific Items \n- Adjustable color ratios (e.g., 1:1 mix of dark blue and transparent flakes) \n- Temperature-controlled environment (for cooling layers effectively) \n\n### Supplementary \n- Chessboard pattern example (referenced video demonstration)",
"references": "## Articles\n- https://community.preciousplastic.com/library/make-a-mould-to-extrude-beams \n- https://onearmy.github.io/academy/create/design \n- https://community.preciousplastic.com/library/extrude-different-textures \n\n## Youtube\n- https://www.youtube.com/watch?v=6bb2qIUMVs8 \n- https://www.youtube.com/watch?v=t8PpQtInVhE \n\n## Opensource Designs \n- https://www.instructables.com/Recycled-Plastic-Chessboard-With-Unique-Patterns/ \n- https://www.instructables.com/Automated-Chessboard/ \n\n## Papers \n- https://research.tue.nl/files/72619856/benelearn_2017.pdf"
}

50
howtos/make-great-beam-patterns/index.mdx Normal file
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---
title: Make great beam patterns!
slug: make-great-beam-patterns
description: Occasionally, inquiries arise regarding how to achieve appealing patterns in beams. Interestingly, no special technical methods are employed to accomplish this. The technique involves utilizing a basic steel pipe as a mold and allowing the extruder to perform its function. Here is a method you can attempt to achieve similar results.
tags: ["extrusion","HDPE","PP","LDPE"]
category: Guides
difficulty: Easy
time: < 1 hour
location:
---
import { Image } from 'astro:assets'
# Make great beam patterns!
<Image src={import('./DSC_0675_copy.jpg')} alt="Make great beam patterns!" />
Occasionally, inquiries arise regarding how to achieve appealing patterns in beams. Interestingly, no special technical methods are employed to accomplish this. The technique involves utilizing a basic steel pipe as a mold and allowing the extruder to perform its function. Here is a method you can attempt to achieve similar results.
## Steps
### Step 1: Prepare your blends carefully
To create patterns with distinct layers, a minimum of two colors is required. There is no noticeable difference when working with PP or PE for this purpose. Ensure that color mixes remain separate. In this instance, dark blue was combined with transparent flakes, serving as an effective filler. This results in a decreased requirement for dark blue to achieve the desired effect, as the color pigments are typically potent. For example, combining 2.2 lbs (1 kg) of transparent material with 2.2 lbs (1 kg) of dark blue yields a total of 4.4 lbs (2 kg) of dark blue without compromising color quality. The white used in this process is pure white.
<Image src={import('./Screen_Shot_2020-12-12_at_18.31.26.png')} alt="Screen Shot 2020-12-12 at 18.31.26.png" />
### Step 2: Time to do the cooking!
Insert a few scoops into your extruder, activate the machine, and observe if the material is fully melted. Attach your cold mold and restart the machine. For the initial color, use approximately 3 scoops in total (subtracting any leftover already in the hopper). When the hopper is nearly empty, add 2 scoops of your second color. Continue this process, adjusting quantities, until the mold is filled. Allow it to cool slightly before removal. It has been suggested to cool the mold in water to prevent material from escaping, but this is typically unnecessary in this context.
<Image src={import('./Schermafbeelding_2021-01-08_om_17.07.02.png')} alt="Schermafbeelding 2021-01-08 om 17.07.02.png" />
<Image src={import('./Schermafbeelding_2021-01-08_om_17.07.31.png')} alt="Schermafbeelding 2021-01-08 om 17.07.31.png" />
### Step 3: Unboxing and see what came out
It is time to examine the outcome of the mixture. When you begin cutting the beam into smaller segments, you will notice an interesting change in the pattern. The most plausible explanation is as follows: The first color added adheres to the mold's wall or surface and cools slightly. The core remains fluid, allowing the second color to pass through. Continuously altering the input color will create multiple layers within your beam. Refer to the next step for further theoretical explanation.
<Image src={import('./Screen_Shot_2020-12-12_at_18.35.06.png')} alt="Screen Shot 2020-12-12 at 18.35.06.png" />
<Image src={import('./Screen_Shot_2020-12-12_at_18.35.25.png')} alt="Screen Shot 2020-12-12 at 18.35.25.png" />
<Image src={import('./Screen_Shot_2020-12-12_at_18.35.58.png')} alt="Screen Shot 2020-12-12 at 18.35.58.png" />
### Step 4: Theory part 2 & proces video
Another important theory is that further into the mold, the plastic cools down, causing a buildup of pressure to facilitate the plastic flow. The farther from the inlet, the patterns become intriguing due to variations in temperature, flow, and pressure. This is particularly interesting with square tubes, as the corners cause the flow to slow. I assume a round tube will only produce circular patterns.
Watch the video to see the creation of a chessboard with these remarkable beams. Thank you for reading, and enjoy creating your patterns!

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## Articles
- https://community.preciousplastic.com/library/make-a-mould-to-extrude-beams
- https://onearmy.github.io/academy/create/design
- https://community.preciousplastic.com/library/extrude-different-textures
## Youtube
- https://www.youtube.com/watch?v=6bb2qIUMVs8
- https://www.youtube.com/watch?v=t8PpQtInVhE
## Opensource Designs
- https://www.instructables.com/Recycled-Plastic-Chessboard-With-Unique-Patterns/
- https://www.instructables.com/Automated-Chessboard/
## Papers
- https://research.tue.nl/files/72619856/benelearn_2017.pdf

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### Hardware
- Basic steel pipe mold (used for shaping beams)
- Extruder machine (melts and processes plastic)
- Hopper (feeds material into the extruder)
### Materials
- Minimum two colored plastics (e.g., dark blue and white)
- Transparent flakes (act as filler for color dilution)
- Pure white plastic (no additives for brighter results)
### Tools
- Scoops (for adding measured quantities of plastic)
- Water (optional cooling aid for mold stabilization)
### Process-Specific Items
- Adjustable color ratios (e.g., 1:1 mix of dark blue and transparent flakes)
- Temperature-controlled environment (for cooling layers effectively)
### Supplementary
- Chessboard pattern example (referenced video demonstration)

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---
title: No Touch Tool with 3D printed mould
slug: no-touch-tool-with-3d-printed-mould
description: Create a tool for interacting with high-contact areas like door handles, pin pads, and light switches, so your hands remain untouched. It is made from 3D-printed nylon to enable rapid production of molds to address the situation promptly.
tags: ["LDPE","mould","product","injection"]
category: Moulds
difficulty: Medium
time: < 1 week
keywords: No Touch Tool, 3D-printed molds, injection molding, high-contact surfaces, nylon molds, plastic injection process, LDPE plastic, door handle tool, contamination reduction, Lancaster UK
location: Lancaster, United Kingdom of Great Britain and Northern Ireland (the)
---
# No Touch Tool with 3D printed mould
![No Touch Tool with 3D printed mould](20200610_130653-18391d2f2f8-18391d426ff.png)
Create a tool for interacting with high-contact areas like door handles, pin pads, and light switches, so your hands remain untouched. It is made from 3D-printed nylon to enable rapid production of molds to address the situation promptly.
User Location: Lancaster, United Kingdom of Great Britain and Northern Ireland (the)
## Steps
### Step 1: Make or buy the mould
Nylon was used for the mold due to its melting temperature being significantly higher than that of LDPE, which is used for creating the No Touch Tools. The use of 3D printed molds ensures that only the exact amount of plastic necessary is consumed. Although metal molds are preferred for their longevity and quality, they incur higher costs and environmental impact. The nylon molds have undergone over 100 injections with minimal wear, performing well at a fraction of the cost of metal molds.
The molds were printed using an Ultimaker 3 3D printer.
![3D printing.jpg](./3D_printing.jpg)
![383bf69d-ce83-4839-b0a2-d3e06588a402.jpg](./383bf69d-ce83-4839-b0a2-d3e06588a402.jpg)
### Step 2: Make a clamp for the mould
We utilized metal plates on each side of the mold to apply even pressure and disperse heat. Designing bolt slots in the mold halves to clamp them directly is a viable approach. Initially, our molds incorporated through-bolts, which proved impractical. We swiftly adopted a substantial 10 mm (0.39 in) steel plate on both sides of the mold, secured with M10 bolts. This configuration is efficient, allowing easy removal of the molds from the clamp, separation of the part, and reassembly upon completion.
![IMG_5240.jpg](./IMG_5240.jpg)
### Step 3: Inject into the mould
We use LDPE obtained from wheel nut indicators, which are vibrantly colored and of excellent quality. It injects effectively at temperatures between 160-170°C (320-338°F). For each tool, we place 40 grams (1.41 ounces) of plastic into the injection molder, accounting for some initial leakage to ensure smooth plastic flow and potential overflow at the end to guarantee the mold is completely filled.
The plastic is injected manually at a relatively slow pace, and pressure is maintained once the mold is filled, as indicated by material overflow at the top. Utilizing nylon molds insulates the injected plastic, preventing rapid cooling and necessitating maintained pressure to prevent escape post-injection.
![Filling injector.jpg](./Filling_injector.jpg)
![20200723_142104.jpg](./20200723_142104.jpg)
### Step 4: Leave to cool and separate
After injection, allow the molds to remain clamped for 3 minutes to cool before removing the No Touch Tool from the mold. Removing the part too soon may result in deformation due to its softness. Conversely, if left for more than 6 minutes, shrinkage may cause it to adhere to the sides, making release difficult.
Unclamp the mold, carefully peel the part from the mold, and allow the molds to cool. Given that it is a plastic mold, it retains heat longer, which can pose challenges during consecutive injections. Using a fan can expedite this cooling process.
Employing multiple molds and clamps facilitates rapid cycle times, allowing simultaneous injection of subsequent tools while preceding ones cool.
![20200610_130653.jpg](./20200610_130653.jpg)
![WhatsApp Image 2020-07-21 at 18.20.46 (2).jpeg](./WhatsApp_Image_2020-07-21_at_18.20.46_2.jpeg)
### Step 5: Finishing
Cut away the sprue using a sharp knife.
Remove any excess material that may have occurred.
Drill a hole for a keyring at the bottom.
Attach a retractable lanyard, which helps keep the tool accessible while reducing the risk of contamination.
![20200723_141726.jpg](./20200723_141726.jpg)
![20200723_141750.jpg](./20200723_141750.jpg)
![20200723_141918.jpg](./20200723_141918.jpg)
### Step 6: Finished!
Keep your hands away from frequently touched surfaces and use the tool instead.
Stay safe.
![ntt-white-bkgd.png](./ntt-white-bkgd.png)
![No Touch Tool Door.jpg](./No_Touch_Tool_Door.jpg)
![No Touch Tool Pinpad.jpg](./No_Touch_Tool_Pinpad.jpg)
### Step 7: Bonus: Speed up the process
To meet demand or lower the cost of tools, several methods can expedite the process:
1. Preheat the plastic before insertion into the injector.
Consider using an oven to preheat the shreds instead of an extruder.
2. Utilize multiple molds.
This allows products to cool while injecting others.
3. Load the injection tube for multiple shots.
If possible, fill your injector with multiple 1.4 oz (40 g) shots of plastic, enabling multiple injections at once.
![background.jpg](./background.jpg)
![no-touch-tool-18391d343bd.jpg](./no-touch-tool-18391d343bd.jpg)
## Resources
### Hardware
- Ultimaker 3 3D printer ([Product page](https://ultimaker.com/))
- Metal plates (10 mm thickness) with M10 bolts
- Manual plastic injection molder
- Cooling fan
- Drill for keyring hole
### Materials
- Nylon for 3D-printed molds
- LDPE plastic (from wheel nut indicators)
- Steel plates for heat dispersion
- Sharp knife for trimming sprues
- Retractable lanyard
### Software
- 3D modeling software for mold design
### Optional Efficiency Tools
- Oven for plastic preheating
- Multiple molds/clamps for parallel production
- Extruder (alternative to oven for preheating)
- Keyring attachment tools
- Pre-measured plastic shreds (40g portions)
### Post-Processing
- Trimming tools (knife, sandpaper)
- Quality control/testing equipment
- Protective gear for handling hot molds
- Heat-resistant gloves
- Storage solutions for molds/tools
## References
## Articles
- [3D Printed Molds for Injection Molding | igus®](https://www.igus.com/custom-parts-services/3d-printed-molds)
- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/)
- [3D printing low-run injection molds - Protolabs Network](https://www.hubs.com/knowledge-base/3d-printing-low-run-injection-molds/)
## Books
- [How to Make Injection Molds - Plastics Today](https://www.plasticstoday.com/injection-molding/imm-review-how-to-make-injection-molds)
- [Scientific Molding, Recommendations, and Best Practices - Hudson Booksellers](https://www.hudsonbooksellers.com/book/9781569906897)
- [Injection Molds For Beginners - Dokumen](https://dokumen.pub/injection-molds-for-beginners-2e-9781569908181-9781569908198-1569908184.html)
- [Injection Molding Troubleshooting Guide, 3rd ED. - Barnes & Noble](https://www.barnesandnoble.com/w/injection-molding-troubleshooting-guide-3rd-ed-jay-w-carender/1107318566)
## YouTube
- [Designing for Insert Molding - YouTube](https://www.youtube.com/watch?v=8GXZZrRR5ko)
- [STL to 3D Printed Injection Mold | Fusion 360 Mesh - YouTube](https://www.youtube.com/watch?v=KisgYeYaagI)
## Open Source Tools
- [Open Source Injection Molding Simulation - GitHub](https://github.com/krebeljk/openInjMoldSim)
## Material Specifications
- [LDPE Injection Molding Parameters - RapidDirect](https://www.rapiddirect.com/materials/ldpe-injection-molding-service/)
## Process Guides
- [Heat & Cool Technology for Injection Molding - Roctool](https://www.roctool.com/technology/heat-cool-for-plastic-injection-molding/)

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"text": "great way to make the mould! can you please tell me what infill % you used and how many walls to make the mould durable ? i am planing to use PA12 carbon fibre filament from bambulabs , do you thing it is suitable",
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"description": "Create a tool for interacting with high-contact areas like door handles, pin pads, and light switches, so your hands remain untouched. It is made from 3D-printed nylon to enable rapid production of molds to address the situation promptly.",
"steps": [
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"text": "Nylon was used for the mold due to its melting temperature being significantly higher than that of LDPE, which is used for creating the No Touch Tools. The use of 3D printed molds ensures that only the exact amount of plastic necessary is consumed. Although metal molds are preferred for their longevity and quality, they incur higher costs and environmental impact. The nylon molds have undergone over 100 injections with minimal wear, performing well at a fraction of the cost of metal molds.\n\nThe molds were printed using an Ultimaker 3 3D printer.",
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"text": "Nylon was used for the mould as it's melting temperature is much higher than that of LDPE which we use to make the No Touch Tools. We are conscious of consuming virgin plastic but using 3D printed moulds means we're only using the exact amount of plastic required (opposed to CNC Machining sheets of polycarbonate for example). Although metal moulds are ideal for longevity and quality, they do come with a higher carbon footprint and cost. The nylon moulds have so far had over 100 injections with little wear and are holding up very well for a fraction of the cost of a metal mould. \n\nWe printed the moulds using an Ultimaker 3 3D printer.",
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"title": "Make or buy the mould"
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"title": "Make a clamp for the mould ",
"text": "We used plates of metal either side of the mould to apply an even pressure but also wick away some of the heat. You could design bolt slots in the mould halves to clamp them directly. \nInitially our moulds had through-bolts which was of course silly and we quickly moved to a significant 10mm steel plate either side of the mould clamped together with M10 bolts. This setup becomes really slick as you can slide the moulds out of the clamp easily, separate the part and slot it back together when complete. ",
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"title": "Make a clamp for the mould ",
"text": "We utilized metal plates on each side of the mold to apply even pressure and disperse heat. Designing bolt slots in the mold halves to clamp them directly is a viable approach. Initially, our molds incorporated through-bolts, which proved impractical. We swiftly adopted a substantial 10 mm (0.39 in) steel plate on both sides of the mold, secured with M10 bolts. This configuration is efficient, allowing easy removal of the molds from the clamp, separation of the part, and reassembly upon completion."
},
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"text": "We use LDPE obtained from wheel nut indicators, which are vibrantly colored and of excellent quality. It injects effectively at temperatures between 160-170°C (320-338°F). For each tool, we place 40 grams (1.41 ounces) of plastic into the injection molder, accounting for some initial leakage to ensure smooth plastic flow and potential overflow at the end to guarantee the mold is completely filled. \n\nThe plastic is injected manually at a relatively slow pace, and pressure is maintained once the mold is filled, as indicated by material overflow at the top. Utilizing nylon molds insulates the injected plastic, preventing rapid cooling and necessitating maintained pressure to prevent escape post-injection.",
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"text": "We use LDPE sourced from wheel nut indicators (Checkpoints) which is vibrantly coloured and very nice quality to work with. It injects nicely between 160-170*C. \nFor each tool we put 40g of plastic into the injection moulder - accounting for some leakage at the beginning to ensure the plastic is flowing nicely and over-spill at the end to ensure the mould is 100% filled. \nWe inject the plastic relatively slowly by hand and hold the pressure once the mould is filled (indicated by when it overflows at the top). Using nylon moulds means that the injected plastic is insulated so it doesn't cool quickly so wants to escape if you don't hold the pressure after injecting. ",
"title": "Inject into the mould"
},
{
"text": "After injecting, leave the moulds clamped to cool for 3 minutes before releasing the No Touch Tool from the mould. If you take out the part too early, it may be soft and you risk deforming it. \nEqually, don't leave it in longer than 6 minutes as the shrinkage may cause it to hug the sides which makes it much harder to release! \n\nUnclamp the mould, peel the part from the mould and leave the moulds to cool (being a plastic mould, it keeps warm for longer which can cause issues over multiple injections). A fan can help this process. \n\nUsing multiple moulds and clamps here enables you to get quick cycle times - you can be injecting the next tools whilst the previous ones cool for example. ",
"title": "Leave to cool and separate",
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"text": "Cut away the sprue using a sharp knife.\nCut away any flashing that may have occurred.\nDrill a hole for a keyring in the bottom. \nAttach a retractable lanyard which helps keep the tool keep out of pockets and reduce contamination risk but remains close to hand. ",
"title": "Finishing",
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"title": "Finished! ",
"_animationKey": "uniqueba3x4e",
"text": "Keep your hands away from high-contact surfaces and use the tool instead!\n\nStay safe out there. "
"title": "Leave to cool and separate",
"text": "After injection, allow the molds to remain clamped for 3 minutes to cool before removing the No Touch Tool from the mold. Removing the part too soon may result in deformation due to its softness. Conversely, if left for more than 6 minutes, shrinkage may cause it to adhere to the sides, making release difficult.\n\nUnclamp the mold, carefully peel the part from the mold, and allow the molds to cool. Given that it is a plastic mold, it retains heat longer, which can pose challenges during consecutive injections. Using a fan can expedite this cooling process.\n\nEmploying multiple molds and clamps facilitates rapid cycle times, allowing simultaneous injection of subsequent tools while preceding ones cool."
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"text": "Cut away the sprue using a sharp knife. \nRemove any excess material that may have occurred. \nDrill a hole for a keyring at the bottom. \nAttach a retractable lanyard, which helps keep the tool accessible while reducing the risk of contamination.",
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"text": "Keep your hands away from frequently touched surfaces and use the tool instead.\n\nStay safe.",
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"text": "To meet demand or lower the price point of the tools, there are a number of ways you can speed up the process:\n\n1. Heat the plastic before putting into the injector like Qi-Tech \nhttps://community.preciousplastic.com/how-to/rapid-fire-method-for-injection--300-face-shields-a-day\nYou can also use an oven to pre-heat the shreds rather than an extruder. \n2. Use multiple moulds.\nThis enables you to have some products cooling whilst you inject others. \n3. Fill the injection tube for multiple shots. \nIf you can load your injector with multiple 40g shots of plastic, this will enable you to inject multiple shots at a time. "
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"content": "Create a tool for interacting with high-contact areas like door handles, pin pads, and light switches, so your hands remain untouched. It is made from 3D-printed nylon to enable rapid production of molds to address the situation promptly.\n\n\nUser Location: Lancaster, United Kingdom of Great Britain and Northern Ireland (the)\n\nNylon was used for the mold due to its melting temperature being significantly higher than that of LDPE, which is used for creating the No Touch Tools. The use of 3D printed molds ensures that only the exact amount of plastic necessary is consumed. Although metal molds are preferred for their longevity and quality, they incur higher costs and environmental impact. The nylon molds have undergone over 100 injections with minimal wear, performing well at a fraction of the cost of metal molds.\n\nThe molds were printed using an Ultimaker 3 3D printer.\n\nWe utilized metal plates on each side of the mold to apply even pressure and disperse heat. Designing bolt slots in the mold halves to clamp them directly is a viable approach. Initially, our molds incorporated through-bolts, which proved impractical. We swiftly adopted a substantial 10 mm (0.39 in) steel plate on both sides of the mold, secured with M10 bolts. This configuration is efficient, allowing easy removal of the molds from the clamp, separation of the part, and reassembly upon completion.\n\nWe use LDPE obtained from wheel nut indicators, which are vibrantly colored and of excellent quality. It injects effectively at temperatures between 160-170°C (320-338°F). For each tool, we place 40 grams (1.41 ounces) of plastic into the injection molder, accounting for some initial leakage to ensure smooth plastic flow and potential overflow at the end to guarantee the mold is completely filled. \n\nThe plastic is injected manually at a relatively slow pace, and pressure is maintained once the mold is filled, as indicated by material overflow at the top. Utilizing nylon molds insulates the injected plastic, preventing rapid cooling and necessitating maintained pressure to prevent escape post-injection.\n\nAfter injection, allow the molds to remain clamped for 3 minutes to cool before removing the No Touch Tool from the mold. Removing the part too soon may result in deformation due to its softness. Conversely, if left for more than 6 minutes, shrinkage may cause it to adhere to the sides, making release difficult.\n\nUnclamp the mold, carefully peel the part from the mold, and allow the molds to cool. Given that it is a plastic mold, it retains heat longer, which can pose challenges during consecutive injections. Using a fan can expedite this cooling process.\n\nEmploying multiple molds and clamps facilitates rapid cycle times, allowing simultaneous injection of subsequent tools while preceding ones cool.\n\nCut away the sprue using a sharp knife. \nRemove any excess material that may have occurred. \nDrill a hole for a keyring at the bottom. \nAttach a retractable lanyard, which helps keep the tool accessible while reducing the risk of contamination.\n\nKeep your hands away from frequently touched surfaces and use the tool instead.\n\nStay safe.\n\nTo meet demand or lower the cost of tools, several methods can expedite the process:\n\n1. Preheat the plastic before insertion into the injector. \n Consider using an oven to preheat the shreds instead of an extruder.\n2. Utilize multiple molds.\n This allows products to cool while injecting others.\n3. Load the injection tube for multiple shots.\n If possible, fill your injector with multiple 1.4 oz (40 g) shots of plastic, enabling multiple injections at once.",
"keywords": "No Touch Tool, 3D-printed molds, injection molding, high-contact surfaces, nylon molds, plastic injection process, LDPE plastic, door handle tool, contamination reduction, Lancaster UK",
"resources": "### Hardware\n- Ultimaker 3 3D printer ([Product page](https://ultimaker.com/)) \n- Metal plates (10 mm thickness) with M10 bolts \n- Manual plastic injection molder \n- Cooling fan \n- Drill for keyring hole \n\n### Materials\n- Nylon for 3D-printed molds \n- LDPE plastic (from wheel nut indicators) \n- Steel plates for heat dispersion \n- Sharp knife for trimming sprues \n- Retractable lanyard \n\n### Software\n- 3D modeling software for mold design \n\n### Optional Efficiency Tools\n- Oven for plastic preheating \n- Multiple molds/clamps for parallel production \n- Extruder (alternative to oven for preheating) \n- Keyring attachment tools \n- Pre-measured plastic shreds (40g portions) \n\n### Post-Processing\n- Trimming tools (knife, sandpaper) \n- Quality control/testing equipment \n- Protective gear for handling hot molds \n- Heat-resistant gloves \n- Storage solutions for molds/tools",
"references": "## Articles \n- [3D Printed Molds for Injection Molding | igus®](https://www.igus.com/custom-parts-services/3d-printed-molds) \n- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/) \n- [3D printing low-run injection molds - Protolabs Network](https://www.hubs.com/knowledge-base/3d-printing-low-run-injection-molds/) \n\n## Books \n- [How to Make Injection Molds - Plastics Today](https://www.plasticstoday.com/injection-molding/imm-review-how-to-make-injection-molds) \n- [Scientific Molding, Recommendations, and Best Practices - Hudson Booksellers](https://www.hudsonbooksellers.com/book/9781569906897) \n- [Injection Molds For Beginners - Dokumen](https://dokumen.pub/injection-molds-for-beginners-2e-9781569908181-9781569908198-1569908184.html) \n- [Injection Molding Troubleshooting Guide, 3rd ED. - Barnes & Noble](https://www.barnesandnoble.com/w/injection-molding-troubleshooting-guide-3rd-ed-jay-w-carender/1107318566) \n\n## YouTube \n- [Designing for Insert Molding - YouTube](https://www.youtube.com/watch?v=8GXZZrRR5ko) \n- [STL to 3D Printed Injection Mold | Fusion 360 Mesh - YouTube](https://www.youtube.com/watch?v=KisgYeYaagI) \n\n## Open Source Tools \n- [Open Source Injection Molding Simulation - GitHub](https://github.com/krebeljk/openInjMoldSim) \n\n## Material Specifications \n- [LDPE Injection Molding Parameters - RapidDirect](https://www.rapiddirect.com/materials/ldpe-injection-molding-service/) \n\n## Process Guides \n- [Heat & Cool Technology for Injection Molding - Roctool](https://www.roctool.com/technology/heat-cool-for-plastic-injection-molding/)"
}

109
howtos/no-touch-tool-with-3d-printed-mould/index.mdx Normal file
View File

@ -0,0 +1,109 @@
---
title: No Touch Tool with 3D printed mould
slug: no-touch-tool-with-3d-printed-mould
description: Create a tool for interacting with high-contact areas like door handles, pin pads, and light switches, so your hands remain untouched. It is made from 3D-printed nylon to enable rapid production of molds to address the situation promptly.
tags: ["LDPE","mould","product","injection"]
category: Moulds
difficulty: Medium
time: < 1 week
location: Lancaster, United Kingdom of Great Britain and Northern Ireland (the)
---
import { Image } from 'astro:assets'
# No Touch Tool with 3D printed mould
<Image src={import('./20200610_130653-18391d2f2f8-18391d426ff.png')} alt="No Touch Tool with 3D printed mould" />
Create a tool for interacting with high-contact areas like door handles, pin pads, and light switches, so your hands remain untouched. It is made from 3D-printed nylon to enable rapid production of molds to address the situation promptly.
User Location: Lancaster, United Kingdom of Great Britain and Northern Ireland (the)
## Steps
### Step 1: Make or buy the mould
Nylon was used for the mold due to its melting temperature being significantly higher than that of LDPE, which is used for creating the No Touch Tools. The use of 3D printed molds ensures that only the exact amount of plastic necessary is consumed. Although metal molds are preferred for their longevity and quality, they incur higher costs and environmental impact. The nylon molds have undergone over 100 injections with minimal wear, performing well at a fraction of the cost of metal molds.
The molds were printed using an Ultimaker 3 3D printer.
<Image src={import('./3D_printing.jpg')} alt="3D printing.jpg" />
<Image src={import('./383bf69d-ce83-4839-b0a2-d3e06588a402.jpg')} alt="383bf69d-ce83-4839-b0a2-d3e06588a402.jpg" />
### Step 2: Make a clamp for the mould
We utilized metal plates on each side of the mold to apply even pressure and disperse heat. Designing bolt slots in the mold halves to clamp them directly is a viable approach. Initially, our molds incorporated through-bolts, which proved impractical. We swiftly adopted a substantial 10 mm (0.39 in) steel plate on both sides of the mold, secured with M10 bolts. This configuration is efficient, allowing easy removal of the molds from the clamp, separation of the part, and reassembly upon completion.
<Image src={import('./IMG_5240.jpg')} alt="IMG_5240.jpg" />
### Step 3: Inject into the mould
We use LDPE obtained from wheel nut indicators, which are vibrantly colored and of excellent quality. It injects effectively at temperatures between 160-170°C (320-338°F). For each tool, we place 40 grams (1.41 ounces) of plastic into the injection molder, accounting for some initial leakage to ensure smooth plastic flow and potential overflow at the end to guarantee the mold is completely filled.
The plastic is injected manually at a relatively slow pace, and pressure is maintained once the mold is filled, as indicated by material overflow at the top. Utilizing nylon molds insulates the injected plastic, preventing rapid cooling and necessitating maintained pressure to prevent escape post-injection.
<Image src={import('./Filling_injector.jpg')} alt="Filling injector.jpg" />
<Image src={import('./20200723_142104.jpg')} alt="20200723_142104.jpg" />
### Step 4: Leave to cool and separate
After injection, allow the molds to remain clamped for 3 minutes to cool before removing the No Touch Tool from the mold. Removing the part too soon may result in deformation due to its softness. Conversely, if left for more than 6 minutes, shrinkage may cause it to adhere to the sides, making release difficult.
Unclamp the mold, carefully peel the part from the mold, and allow the molds to cool. Given that it is a plastic mold, it retains heat longer, which can pose challenges during consecutive injections. Using a fan can expedite this cooling process.
Employing multiple molds and clamps facilitates rapid cycle times, allowing simultaneous injection of subsequent tools while preceding ones cool.
<Image src={import('./20200610_130653.jpg')} alt="20200610_130653.jpg" />
<Image src={import('./WhatsApp_Image_2020-07-21_at_18.20.46_2.jpeg')} alt="WhatsApp Image 2020-07-21 at 18.20.46 (2).jpeg" />
### Step 5: Finishing
Cut away the sprue using a sharp knife.
Remove any excess material that may have occurred.
Drill a hole for a keyring at the bottom.
Attach a retractable lanyard, which helps keep the tool accessible while reducing the risk of contamination.
<Image src={import('./20200723_141726.jpg')} alt="20200723_141726.jpg" />
<Image src={import('./20200723_141750.jpg')} alt="20200723_141750.jpg" />
<Image src={import('./20200723_141918.jpg')} alt="20200723_141918.jpg" />
### Step 6: Finished!
Keep your hands away from frequently touched surfaces and use the tool instead.
Stay safe.
<Image src={import('./ntt-white-bkgd.png')} alt="ntt-white-bkgd.png" />
<Image src={import('./No_Touch_Tool_Door.jpg')} alt="No Touch Tool Door.jpg" />
<Image src={import('./No_Touch_Tool_Pinpad.jpg')} alt="No Touch Tool Pinpad.jpg" />
### Step 7: Bonus: Speed up the process
To meet demand or lower the cost of tools, several methods can expedite the process:
1. Preheat the plastic before insertion into the injector.
Consider using an oven to preheat the shreds instead of an extruder.
2. Utilize multiple molds.
This allows products to cool while injecting others.
3. Load the injection tube for multiple shots.
If possible, fill your injector with multiple 1.4 oz (40 g) shots of plastic, enabling multiple injections at once.
<Image src={import('./background.jpg')} alt="background.jpg" />
<Image src={import('./no-touch-tool-18391d343bd.jpg')} alt="no-touch-tool-18391d343bd.jpg" />

23
howtos/no-touch-tool-with-3d-printed-mould/references.md Normal file
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@ -0,0 +1,23 @@
## Articles
- [3D Printed Molds for Injection Molding | igus®](https://www.igus.com/custom-parts-services/3d-printed-molds)
- [DIY Injection Molding: How to Mold Plastic Parts In-House - Formlabs](https://formlabs.com/blog/diy-injection-molding/)
- [3D printing low-run injection molds - Protolabs Network](https://www.hubs.com/knowledge-base/3d-printing-low-run-injection-molds/)
## Books
- [How to Make Injection Molds - Plastics Today](https://www.plasticstoday.com/injection-molding/imm-review-how-to-make-injection-molds)
- [Scientific Molding, Recommendations, and Best Practices - Hudson Booksellers](https://www.hudsonbooksellers.com/book/9781569906897)
- [Injection Molds For Beginners - Dokumen](https://dokumen.pub/injection-molds-for-beginners-2e-9781569908181-9781569908198-1569908184.html)
- [Injection Molding Troubleshooting Guide, 3rd ED. - Barnes & Noble](https://www.barnesandnoble.com/w/injection-molding-troubleshooting-guide-3rd-ed-jay-w-carender/1107318566)
## YouTube
- [Designing for Insert Molding - YouTube](https://www.youtube.com/watch?v=8GXZZrRR5ko)
- [STL to 3D Printed Injection Mold | Fusion 360 Mesh - YouTube](https://www.youtube.com/watch?v=KisgYeYaagI)
## Open Source Tools
- [Open Source Injection Molding Simulation - GitHub](https://github.com/krebeljk/openInjMoldSim)
## Material Specifications
- [LDPE Injection Molding Parameters - RapidDirect](https://www.rapiddirect.com/materials/ldpe-injection-molding-service/)
## Process Guides
- [Heat & Cool Technology for Injection Molding - Roctool](https://www.roctool.com/technology/heat-cool-for-plastic-injection-molding/)

30
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@ -0,0 +1,30 @@
### Hardware
- Ultimaker 3 3D printer ([Product page](https://ultimaker.com/))
- Metal plates (10 mm thickness) with M10 bolts
- Manual plastic injection molder
- Cooling fan
- Drill for keyring hole
### Materials
- Nylon for 3D-printed molds
- LDPE plastic (from wheel nut indicators)
- Steel plates for heat dispersion
- Sharp knife for trimming sprues
- Retractable lanyard
### Software
- 3D modeling software for mold design
### Optional Efficiency Tools
- Oven for plastic preheating
- Multiple molds/clamps for parallel production
- Extruder (alternative to oven for preheating)
- Keyring attachment tools
- Pre-measured plastic shreds (40g portions)
### Post-Processing
- Trimming tools (knife, sandpaper)
- Quality control/testing equipment
- Protective gear for handling hot molds
- Heat-resistant gloves
- Storage solutions for molds/tools

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---
title: Phonecase mould from a resin printer
slug: phonecase-mould-from-a-resin-printer
description: This guide provides instructions on designing and printing a phone cover mold using a resin printer. It details the steps involved in creating a phone cover mold and offers useful tips on mold design, resin printing, and manufacturing.
The zip file contains:
1. 3D files - SLA phone cover mold (step)
2. 3D files - SLA phone cover mold (stl)
3. Readme with links to the resin and printer (txt)
4. Technical drawing of the mold (pdf)
tags: ["PP","research","injection"]
category: uncategorized
difficulty: Hard
time: < 1 week
keywords: resin printer, phone cover mold, 3D printing, Fusion 360, GrabCAD, SLA printer, CAD software, 3D model download, mold manufacturing, injection molding
location: Lorrach, Germany
---
# Phonecase mould from a resin printer
![Phonecase mould from a resin printer](_DSC9733-189ab337d9e.jpg)
This guide provides instructions on designing and printing a phone cover mold using a resin printer. It details the steps involved in creating a phone cover mold and offers useful tips on mold design, resin printing, and manufacturing.
The zip file contains:
1. 3D files - SLA phone cover mold (step)
2. 3D files - SLA phone cover mold (stl)
3. Readme with links to the resin and printer (txt)
4. Technical drawing of the mold (pdf)
User Location: Lorrach, Germany
## Steps
### Step 1: Download a phone model
Before modeling the mold, obtain a 3D model of the phone case you wish to create. First, locate the phone model online using a CAD library such as GrabCAD.
1. Access GrabCAD and search for the desired phone model for your phone case.
2. Download the model (a STEP file is recommended).
3. Open the model in your CAD software.
While several websites provide CAD libraries, GrabCAD is commonly used due to its extensive selection of 3D files and free access after registration.
Link to GrabCAD: [grabcad.com/library](https://grabcad.com/library)
![Folie7-189bff2ef50.PNG](./Folie7-189bff2ef50.PNG)
![Folie1-189bff3034a.PNG](./Folie1-189bff3034a.PNG)
![Folie2-189bff31015.PNG](./Folie2-189bff31015.PNG)
### Step 2: Design the mould (with Fusion360)
To design a phone cover, it is first necessary to download the phone model. Thereafter, this model can be utilized to create the shape of the cover and the mold. A recommended software for 3D design is Fusion360, which is suitable for both novices and experienced users.
Below are links to two instructive videos that demonstrate how to use Fusion360 for this project.
The first video is provided by "Product Design Online," a channel that offers detailed tutorials on Fusion360. This video provides a step-by-step guide on designing a phone case model.
Making a phone cover model: [YouTube Video](https://www.youtube.com/watch?v=1MmjBLYMNWY)
The second video is from Lars Christensen's channel, where a mold is created in a series of three videos.
Lars making a mold in Fusion: [YouTube Video](https://www.youtube.com/watch?v=_hgmwhde1So)
Frequently, completed phone cover models are available on GrabCad, eliminating the need to design them independently and allowing one to proceed directly with mold creation.
![Capture-1899ccec87e.PNG](./Capture-1899ccec87e.PNG)
![crosssec2-1899cea11fe.PNG](./crosssec2-1899cea11fe.PNG)
![crosssec1-1899cea4efc.PNG](./crosssec1-1899cea4efc.PNG)
### Step 3: Tips for using Fusion360
Certainly. Below is the revised text in Markdown format:
---
Fusion 360 is a powerful software tool utilized since 2018 for various projects. Although the software requires a subscription, there are options to mitigate the cost.
One alternative is acquiring the educational license if you are a university student. This license is complimentary and remains valid as long as enrollment status is maintained, contingent upon providing proof of student status.
Another option is the hobbyist version of Fusion 360, which includes certain file format limitations. While less familiar with this version, the educational license has proven effective.
Link to the educational download: [autodesk.com/products/fusion-360/education](https://www.autodesk.com/products/fusion-360/education)
![Folie5-189bff2ab49.PNG](./Folie5-189bff2ab49.PNG)
![Folie3-189bff2c31e.PNG](./Folie3-189bff2c31e.PNG)
![Folie4-189bff2d3ae.PNG](./Folie4-189bff2d3ae.PNG)
### Step 4: 3D print the mould or give it to a manufacturer
Once the mold is designed, you can 3D print it using an SLA printer. SLA stands for stereolithography, a process that uses light to cure liquid resin into solid layers. If a printer is unavailable, you can outsource the job to an online manufacturer.
Make it yourself:
1. Prepare your model and materials. Slice your model into layers using software such as ChiTuBox. Select a high-temperature resin for your mold.
2. Pour the resin into the tank and start your print. There are numerous tutorials available on operating an SLA printer for this purpose.
3. Wait for the model to print.
Outsource to an online manufacturer:
You may consider using online services, which often provide reasonable prices and have produced high-quality parts.
Link to Xometry: [xometry.com](https://www.xometry.com)
![Folie6-189bff264b4.PNG](./Folie6-189bff264b4.PNG)
![Xometry-189bff278c2.PNG](./Xometry-189bff278c2.PNG)
![asdf-189bff2881c.PNG](./asdf-189bff2881c.PNG)
### Step 5: Things to know when designing a resin mould
The resin material differs significantly from aluminum, primarily in thermal conductivity—a critical factor affecting heating and cooling times, as well as the quality and cost of molded parts.
Resin transfers heat less efficiently, allowing for the design of thinner walls in finished parts. However, this characteristic also results in longer cooling times. Depending on the part's shape, resin molds may be beneficial; the slower cooling process generally reduces tension in finished parts and lowers the risk of cracking or warping.
Conversely, resin is more brittle than aluminum, necessitating careful handling. Resin molds are susceptible to damage from abrasion or impact and may require more frequent maintenance or replacement.
![_DSC9721-189bb74a83e.JPG](./_DSC9721-189bb74a83e.JPG)
![_DSC9716-189bb74c076.JPG](./_DSC9716-189bb74c076.JPG)
![_DSC9755-189bb7502ac.JPG](./_DSC9755-189bb7502ac.JPG)
### Step 6: Using the mould for automatic injection molding
I developed this resin mold design for an automatic injection molding machine, which has been my primary project. The machine is fully automated and utilizes ejector pins to remove the completed parts. Consequently, the insert part of the mold contains four holes for the ejector pins.
For a demonstration of the ejecting mechanism with the pins installed, I have created a YouTube video showcasing the process.
I hope this tutorial has been beneficial. For more details on this mold or similar projects, feel free to visit my channel.
[instagram.com/sotop_recycling](https://www.instagram.com/sotop_recycling/)
## Resources
---
To design and print a phone cover mold using a resin printer, the following tools and resources are required:
### Software Tools
- **GrabCAD** ([grabcad.com](https://grabcad.com/library)) – Download phone model STEP files
- **Fusion 360** ([education link](https://www.autodesk.com/products/fusion-360/education)) – For mold design (educational license recommended)
- **ChiTuBox** – Slicing software for resin 3D printing
### 3D Printing Hardware
- **SLA resin printer** – Stereolithography printer for curing resin layer-by-layer
### Resin Material
- **High-temperature resin** – Required for mold durability during injection
### Online Manufacturing Services
- **Xometry** ([xometry.com](https://www.xometry.com)) – For outsourcing SLA printing
For detailed tutorials, refer to the provided [Fusion 360 video guides](#) and the project’s [Instagram channel](https://www.instagram.com/sotop_recycling/).
## References
---
## Articles & CAD Libraries
- [GrabCAD Library](https://grabcad.com/library)
## YouTube Tutorials
- [Fusion 360 Phone Case Design Tutorial](https://www.youtube.com/watch?v=1MmjBLYMNWY)
- [Mold Design in Fusion 360](https://www.youtube.com/watch?v=_hgmwhde1So)
## Software & Tools
- [Fusion 360 Educational License](https://www.autodesk.com/products/fusion-360/education)
## Manufacturing Services
- [Xometry (3D Printing/CNC)](https://www.xometry.com)
## Social Media & Community
- [SOTOP Recycling Instagram](https://www.instagram.com/sotop_recycling/)

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---
title: Phonecase mould from a resin printer
slug: phonecase-mould-from-a-resin-printer
description: This guide provides instructions on designing and printing a phone cover mold using a resin printer. It details the steps involved in creating a phone cover mold and offers useful tips on mold design, resin printing, and manufacturing.
The zip file contains:
1. 3D files - SLA phone cover mold (step)
2. 3D files - SLA phone cover mold (stl)
3. Readme with links to the resin and printer (txt)
4. Technical drawing of the mold (pdf)
tags: ["PP","research","injection"]
category: uncategorized
difficulty: Hard
time: < 1 week
location: Lorrach, Germany
---
import { Image } from 'astro:assets'
# Phonecase mould from a resin printer
<Image src={import('./_DSC9733-189ab337d9e.jpg')} alt="Phonecase mould from a resin printer" />
This guide provides instructions on designing and printing a phone cover mold using a resin printer. It details the steps involved in creating a phone cover mold and offers useful tips on mold design, resin printing, and manufacturing.
The zip file contains:
1. 3D files - SLA phone cover mold (step)
2. 3D files - SLA phone cover mold (stl)
3. Readme with links to the resin and printer (txt)
4. Technical drawing of the mold (pdf)
User Location: Lorrach, Germany
## Steps
### Step 1: Download a phone model
Before modeling the mold, obtain a 3D model of the phone case you wish to create. First, locate the phone model online using a CAD library such as GrabCAD.
1. Access GrabCAD and search for the desired phone model for your phone case.
2. Download the model (a STEP file is recommended).
3. Open the model in your CAD software.
While several websites provide CAD libraries, GrabCAD is commonly used due to its extensive selection of 3D files and free access after registration.
Link to GrabCAD: [grabcad.com/library](https://grabcad.com/library)
<Image src={import('./Folie7-189bff2ef50.PNG')} alt="Folie7-189bff2ef50.PNG" />
<Image src={import('./Folie1-189bff3034a.PNG')} alt="Folie1-189bff3034a.PNG" />
<Image src={import('./Folie2-189bff31015.PNG')} alt="Folie2-189bff31015.PNG" />
### Step 2: Design the mould (with Fusion360)
To design a phone cover, it is first necessary to download the phone model. Thereafter, this model can be utilized to create the shape of the cover and the mold. A recommended software for 3D design is Fusion360, which is suitable for both novices and experienced users.
Below are links to two instructive videos that demonstrate how to use Fusion360 for this project.
The first video is provided by "Product Design Online," a channel that offers detailed tutorials on Fusion360. This video provides a step-by-step guide on designing a phone case model.
Making a phone cover model: [YouTube Video](https://www.youtube.com/watch?v=1MmjBLYMNWY)
The second video is from Lars Christensen's channel, where a mold is created in a series of three videos.
Lars making a mold in Fusion: [YouTube Video](https://www.youtube.com/watch?v=_hgmwhde1So)
Frequently, completed phone cover models are available on GrabCad, eliminating the need to design them independently and allowing one to proceed directly with mold creation.
<Image src={import('./Capture-1899ccec87e.PNG')} alt="Capture-1899ccec87e.PNG" />
<Image src={import('./crosssec2-1899cea11fe.PNG')} alt="crosssec2-1899cea11fe.PNG" />
<Image src={import('./crosssec1-1899cea4efc.PNG')} alt="crosssec1-1899cea4efc.PNG" />
### Step 3: Tips for using Fusion360
Certainly. Below is the revised text in Markdown format:
---
Fusion 360 is a powerful software tool utilized since 2018 for various projects. Although the software requires a subscription, there are options to mitigate the cost.
One alternative is acquiring the educational license if you are a university student. This license is complimentary and remains valid as long as enrollment status is maintained, contingent upon providing proof of student status.
Another option is the hobbyist version of Fusion 360, which includes certain file format limitations. While less familiar with this version, the educational license has proven effective.
Link to the educational download: [autodesk.com/products/fusion-360/education](https://www.autodesk.com/products/fusion-360/education)
<Image src={import('./Folie5-189bff2ab49.PNG')} alt="Folie5-189bff2ab49.PNG" />
<Image src={import('./Folie3-189bff2c31e.PNG')} alt="Folie3-189bff2c31e.PNG" />
<Image src={import('./Folie4-189bff2d3ae.PNG')} alt="Folie4-189bff2d3ae.PNG" />
### Step 4: 3D print the mould or give it to a manufacturer
Once the mold is designed, you can 3D print it using an SLA printer. SLA stands for stereolithography, a process that uses light to cure liquid resin into solid layers. If a printer is unavailable, you can outsource the job to an online manufacturer.
Make it yourself:
1. Prepare your model and materials. Slice your model into layers using software such as ChiTuBox. Select a high-temperature resin for your mold.
2. Pour the resin into the tank and start your print. There are numerous tutorials available on operating an SLA printer for this purpose.
3. Wait for the model to print.
Outsource to an online manufacturer:
You may consider using online services, which often provide reasonable prices and have produced high-quality parts.
Link to Xometry: [xometry.com](https://www.xometry.com)
<Image src={import('./Folie6-189bff264b4.PNG')} alt="Folie6-189bff264b4.PNG" />
<Image src={import('./Xometry-189bff278c2.PNG')} alt="Xometry-189bff278c2.PNG" />
<Image src={import('./asdf-189bff2881c.PNG')} alt="asdf-189bff2881c.PNG" />
### Step 5: Things to know when designing a resin mould
The resin material differs significantly from aluminum, primarily in thermal conductivity—a critical factor affecting heating and cooling times, as well as the quality and cost of molded parts.
Resin transfers heat less efficiently, allowing for the design of thinner walls in finished parts. However, this characteristic also results in longer cooling times. Depending on the part's shape, resin molds may be beneficial; the slower cooling process generally reduces tension in finished parts and lowers the risk of cracking or warping.
Conversely, resin is more brittle than aluminum, necessitating careful handling. Resin molds are susceptible to damage from abrasion or impact and may require more frequent maintenance or replacement.
<Image src={import('./_DSC9721-189bb74a83e.JPG')} alt="_DSC9721-189bb74a83e.JPG" />
<Image src={import('./_DSC9716-189bb74c076.JPG')} alt="_DSC9716-189bb74c076.JPG" />
<Image src={import('./_DSC9755-189bb7502ac.JPG')} alt="_DSC9755-189bb7502ac.JPG" />
### Step 6: Using the mould for automatic injection molding
I developed this resin mold design for an automatic injection molding machine, which has been my primary project. The machine is fully automated and utilizes ejector pins to remove the completed parts. Consequently, the insert part of the mold contains four holes for the ejector pins.
For a demonstration of the ejecting mechanism with the pins installed, I have created a YouTube video showcasing the process.
I hope this tutorial has been beneficial. For more details on this mold or similar projects, feel free to visit my channel.
[instagram.com/sotop_recycling](https://www.instagram.com/sotop_recycling/)

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---
## Articles & CAD Libraries
- [GrabCAD Library](https://grabcad.com/library)
## YouTube Tutorials
- [Fusion 360 Phone Case Design Tutorial](https://www.youtube.com/watch?v=1MmjBLYMNWY)
- [Mold Design in Fusion 360](https://www.youtube.com/watch?v=_hgmwhde1So)
## Software & Tools
- [Fusion 360 Educational License](https://www.autodesk.com/products/fusion-360/education)
## Manufacturing Services
- [Xometry (3D Printing/CNC)](https://www.xometry.com)
## Social Media & Community
- [SOTOP Recycling Instagram](https://www.instagram.com/sotop_recycling/)

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@ -0,0 +1,19 @@
---
To design and print a phone cover mold using a resin printer, the following tools and resources are required:
### Software Tools
- **GrabCAD** ([grabcad.com](https://grabcad.com/library)) – Download phone model STEP files
- **Fusion 360** ([education link](https://www.autodesk.com/products/fusion-360/education)) – For mold design (educational license recommended)
- **ChiTuBox** – Slicing software for resin 3D printing
### 3D Printing Hardware
- **SLA resin printer** – Stereolithography printer for curing resin layer-by-layer
### Resin Material
- **High-temperature resin** – Required for mold durability during injection
### Online Manufacturing Services
- **Xometry** ([xometry.com](https://www.xometry.com)) – For outsourcing SLA printing
For detailed tutorials, refer to the provided [Fusion 360 video guides](#) and the project’s [Instagram channel](https://www.instagram.com/sotop_recycling/).

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---
title: Recycle plastic waste into 3d printing filament
slug: recycle-plastic-waste-into-3d-printing-filament
description: This guide demonstrates the process of converting plastic waste into 3D printing filament. Important considerations and various machines are necessary for optimal results.
Watch the instructional video here:
https://youtu.be/IcmKFDxsUgA
Visit our website:
https://www.qitech.de/en/industries
tags: ["hack","other machine","extrusion","shredder"]
category: Guides
difficulty: Easy
time: < 5 hours
keywords: 3D printing filament, plastic waste recycling, extrusion process, filament extruder, JARVIS Shredder, polymer drying, air cooling system, filament winder, 3D printer filament, sustainable 3D printing
location: Darmstadt, Germany
---
# Recycle plastic waste into 3d printing filament
![Recycle plastic waste into 3d printing filament](Ohne_Titel.jpg)
This guide demonstrates the process of converting plastic waste into 3D printing filament. Important considerations and various machines are necessary for optimal results.
Watch the instructional video here:
https://youtu.be/IcmKFDxsUgA
Visit our website:
https://www.qitech.de/en/industries
User Location: Darmstadt, Germany
## Steps
### Step 1: Shredding
Initially, shred the material. We employ the JARVIS Shredder; however, if a shredder is unavailable to you, consider exploring local workshops or employing economical methods such as a hand-cranked shredder, a document shredder, or a combination of scissors and a blender. A more uniform granulate will enhance the quality of the final result.
![1 Shred.jpg](./1_Shred.jpg)
![2 Shred.jpg](./2_Shred.jpg)
![3 Shred.jpg](./3_Shred.jpg)
### Step 2: Drying
The subsequent step involves drying the material. A comprehensive guide on drying polymers with a self-constructed dry box has been previously published.
![1 Drying.jpg](./1_Drying.jpg)
![2 Drying.jpg](./2_Drying.jpg)
### Step 3: Extruding
### Extrusion Process
The following step in the production process is extrusion. To proceed, one must possess an extruder. Options include constructing one independently using available blueprints, or purchasing an extruder from commercial sources. Additionally, a comparative list of various extruder models is available for review on our website: [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision).
Our experience with the sixth-generation extruder has highlighted the importance of several key factors:
1. A well-designed compression screw
2. Accurate temperature measurement and control systems
3. Exchangeable nozzles
![1 Extruding.jpg](./1_Extruding.jpg)
![2 Extruding.jpg](./2_Extruding.jpg)
![3 Extruding.jpg](./3_Extruding.jpg)
### Step 4: Cooling
When the hot filament exits the extruder, it must be cooled and wound onto a spool. You can cool the filament with either air or water. An air cooling system is recommended, as water cooling is complex, and for output under 6.6 lbs/h (3 kg/h), air cooling is sufficient. The simplest and most cost-effective method involves positioning a tower fan horizontally under the filament. Our cooling unit, the JARVIS Airpath, allows precise fan control to harden the filament while keeping it soft enough for easy spooling. The winding process is most effective when individual filament tracks adhere slightly to each other.
![1 Cooling.jpg](./1_Cooling.jpg)
![2 Cooling.jpg](./2_Cooling.jpg)
### Step 5: Winding
Finally, the filament can be wound onto a spool for later use with a 3D printer. A filament winder is necessary, which should include a pull unit, a guider to spool the single tracks from one side to the other, and a turning spool axis. It is crucial to ensure that the filament remains under tension to avoid loose spools.
For this step, we employ the JARVIS Winder. This winding unit automatically adjusts its spool motor speed, facilitating precise winding while maintaining the filament's diameter. Simply insert the filament into the puller, guide it through the guider, and onto the spool.
![1 Winding.jpg](./1_Winding.jpg)
![2 Winding.jpg](./2_Winding.jpg)
### Step 6: Printing
Now you can use your new filament with a 3D printer. Enjoy printing!
![Bildschirmfoto 2021-08-12 um 10.39.12.png](./Bildschirmfoto_2021-08-12_um_10.39.12.png)
## Resources
### Shredding
- JARVIS Shredder
- Hand-cranked shredder (low-cost alternative)
- Document shredder (alternative)
- Scissors and blender combo
- Local workshop access (no shredder)
### Drying
- Self-constructed dry box ([guide via QITECH](https://www.qitech.de/en/industries))
### Extrusion
- Filament extruder ([DIY or pre-built options](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision))
- Compression screw with optimized design
- Precision temperature control system
- Exchangeable nozzles
### Cooling
- JARVIS Airpath ([cooling unit](https://www.qitech.de/en/industries))
- Horizontal tower fan (budget option)
### Winding
- JARVIS Winder ([automated system](https://www.qitech.de/en/industries))
- Filament pull unit
- Filament guider mechanism
- Tension-controlled spool axis
## References
## References
### Articles
- [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision)
### Websites
- [QI Technologies Website](https://www.qitech.de/en/industries)
### Youtube
- [Plastic Waste to 3D Filament Instructional Video](https://youtu.be/IcmKFDxsUgA)

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"text": "### Extrusion Process\n\nThe following step in the production process is extrusion. To proceed, one must possess an extruder. Options include constructing one independently using available blueprints, or purchasing an extruder from commercial sources. Additionally, a comparative list of various extruder models is available for review on our website: [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision).\n\nOur experience with the sixth-generation extruder has highlighted the importance of several key factors:\n\n1. A well-designed compression screw\n2. Accurate temperature measurement and control systems\n3. Exchangeable nozzles"
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@ -279,6 +309,7 @@
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"description": "continent",
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"content": "This guide demonstrates the process of converting plastic waste into 3D printing filament. Important considerations and various machines are necessary for optimal results.\n\nWatch the instructional video here:\nhttps://youtu.be/IcmKFDxsUgA\n\nVisit our website:\nhttps://www.qitech.de/en/industries\n\n\nUser Location: Darmstadt, Germany\n\nInitially, shred the material. We employ the JARVIS Shredder; however, if a shredder is unavailable to you, consider exploring local workshops or employing economical methods such as a hand-cranked shredder, a document shredder, or a combination of scissors and a blender. A more uniform granulate will enhance the quality of the final result.\n\nThe subsequent step involves drying the material. A comprehensive guide on drying polymers with a self-constructed dry box has been previously published.\n\n### Extrusion Process\n\nThe following step in the production process is extrusion. To proceed, one must possess an extruder. Options include constructing one independently using available blueprints, or purchasing an extruder from commercial sources. Additionally, a comparative list of various extruder models is available for review on our website: [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision).\n\nOur experience with the sixth-generation extruder has highlighted the importance of several key factors:\n\n1. A well-designed compression screw\n2. Accurate temperature measurement and control systems\n3. Exchangeable nozzles\n\nWhen the hot filament exits the extruder, it must be cooled and wound onto a spool. You can cool the filament with either air or water. An air cooling system is recommended, as water cooling is complex, and for output under 6.6 lbs/h (3 kg/h), air cooling is sufficient. The simplest and most cost-effective method involves positioning a tower fan horizontally under the filament. Our cooling unit, the JARVIS Airpath, allows precise fan control to harden the filament while keeping it soft enough for easy spooling. The winding process is most effective when individual filament tracks adhere slightly to each other.\n\nFinally, the filament can be wound onto a spool for later use with a 3D printer. A filament winder is necessary, which should include a pull unit, a guider to spool the single tracks from one side to the other, and a turning spool axis. It is crucial to ensure that the filament remains under tension to avoid loose spools.\n\nFor this step, we employ the JARVIS Winder. This winding unit automatically adjusts its spool motor speed, facilitating precise winding while maintaining the filament's diameter. Simply insert the filament into the puller, guide it through the guider, and onto the spool.\n\nNow you can use your new filament with a 3D printer. Enjoy printing!",
"keywords": "3D printing filament, plastic waste recycling, extrusion process, filament extruder, JARVIS Shredder, polymer drying, air cooling system, filament winder, 3D printer filament, sustainable 3D printing",
"resources": "### Shredding\n- JARVIS Shredder \n- Hand-cranked shredder (low-cost alternative) \n- Document shredder (alternative) \n- Scissors and blender combo \n- Local workshop access (no shredder) \n\n### Drying\n- Self-constructed dry box ([guide via QITECH](https://www.qitech.de/en/industries)) \n\n### Extrusion\n- Filament extruder ([DIY or pre-built options](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision)) \n- Compression screw with optimized design \n- Precision temperature control system \n- Exchangeable nozzles \n\n### Cooling\n- JARVIS Airpath ([cooling unit](https://www.qitech.de/en/industries)) \n- Horizontal tower fan (budget option) \n\n### Winding\n- JARVIS Winder ([automated system](https://www.qitech.de/en/industries)) \n- Filament pull unit \n- Filament guider mechanism \n- Tension-controlled spool axis",
"references": "## References\n\n### Articles\n- [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision)\n\n### Websites\n- [QI Technologies Website](https://www.qitech.de/en/industries)\n\n### Youtube\n- [Plastic Waste to 3D Filament Instructional Video](https://youtu.be/IcmKFDxsUgA)"
}

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---
title: Recycle plastic waste into 3d printing filament
slug: recycle-plastic-waste-into-3d-printing-filament
description: This guide demonstrates the process of converting plastic waste into 3D printing filament. Important considerations and various machines are necessary for optimal results.
Watch the instructional video here:
https://youtu.be/IcmKFDxsUgA
Visit our website:
https://www.qitech.de/en/industries
tags: ["hack","other machine","extrusion","shredder"]
category: Guides
difficulty: Easy
time: < 5 hours
location: Darmstadt, Germany
---
import { Image } from 'astro:assets'
# Recycle plastic waste into 3d printing filament
<Image src={import('./Ohne_Titel.jpg')} alt="Recycle plastic waste into 3d printing filament" />
This guide demonstrates the process of converting plastic waste into 3D printing filament. Important considerations and various machines are necessary for optimal results.
Watch the instructional video here:
https://youtu.be/IcmKFDxsUgA
Visit our website:
https://www.qitech.de/en/industries
User Location: Darmstadt, Germany
## Steps
### Step 1: Shredding
Initially, shred the material. We employ the JARVIS Shredder; however, if a shredder is unavailable to you, consider exploring local workshops or employing economical methods such as a hand-cranked shredder, a document shredder, or a combination of scissors and a blender. A more uniform granulate will enhance the quality of the final result.
<Image src={import('./1_Shred.jpg')} alt="1 Shred.jpg" />
<Image src={import('./2_Shred.jpg')} alt="2 Shred.jpg" />
<Image src={import('./3_Shred.jpg')} alt="3 Shred.jpg" />
### Step 2: Drying
The subsequent step involves drying the material. A comprehensive guide on drying polymers with a self-constructed dry box has been previously published.
<Image src={import('./1_Drying.jpg')} alt="1 Drying.jpg" />
<Image src={import('./2_Drying.jpg')} alt="2 Drying.jpg" />
### Step 3: Extruding
### Extrusion Process
The following step in the production process is extrusion. To proceed, one must possess an extruder. Options include constructing one independently using available blueprints, or purchasing an extruder from commercial sources. Additionally, a comparative list of various extruder models is available for review on our website: [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision).
Our experience with the sixth-generation extruder has highlighted the importance of several key factors:
1. A well-designed compression screw
2. Accurate temperature measurement and control systems
3. Exchangeable nozzles
<Image src={import('./1_Extruding.jpg')} alt="1 Extruding.jpg" />
<Image src={import('./2_Extruding.jpg')} alt="2 Extruding.jpg" />
<Image src={import('./3_Extruding.jpg')} alt="3 Extruding.jpg" />
### Step 4: Cooling
When the hot filament exits the extruder, it must be cooled and wound onto a spool. You can cool the filament with either air or water. An air cooling system is recommended, as water cooling is complex, and for output under 6.6 lbs/h (3 kg/h), air cooling is sufficient. The simplest and most cost-effective method involves positioning a tower fan horizontally under the filament. Our cooling unit, the JARVIS Airpath, allows precise fan control to harden the filament while keeping it soft enough for easy spooling. The winding process is most effective when individual filament tracks adhere slightly to each other.
<Image src={import('./1_Cooling.jpg')} alt="1 Cooling.jpg" />
<Image src={import('./2_Cooling.jpg')} alt="2 Cooling.jpg" />
### Step 5: Winding
Finally, the filament can be wound onto a spool for later use with a 3D printer. A filament winder is necessary, which should include a pull unit, a guider to spool the single tracks from one side to the other, and a turning spool axis. It is crucial to ensure that the filament remains under tension to avoid loose spools.
For this step, we employ the JARVIS Winder. This winding unit automatically adjusts its spool motor speed, facilitating precise winding while maintaining the filament's diameter. Simply insert the filament into the puller, guide it through the guider, and onto the spool.
<Image src={import('./1_Winding.jpg')} alt="1 Winding.jpg" />
<Image src={import('./2_Winding.jpg')} alt="2 Winding.jpg" />
### Step 6: Printing
Now you can use your new filament with a 3D printer. Enjoy printing!
<Image src={import('./Bildschirmfoto_2021-08-12_um_10.39.12.png')} alt="Bildschirmfoto 2021-08-12 um 10.39.12.png" />

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## References
### Articles
- [Filament Extruder Comparison](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision)
### Websites
- [QI Technologies Website](https://www.qitech.de/en/industries)
### Youtube
- [Plastic Waste to 3D Filament Instructional Video](https://youtu.be/IcmKFDxsUgA)

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### Shredding
- JARVIS Shredder
- Hand-cranked shredder (low-cost alternative)
- Document shredder (alternative)
- Scissors and blender combo
- Local workshop access (no shredder)
### Drying
- Self-constructed dry box ([guide via QITECH](https://www.qitech.de/en/industries))
### Extrusion
- Filament extruder ([DIY or pre-built options](https://www.qitech.de/en/ind/academy-area/filament-extruder-comparision))
- Compression screw with optimized design
- Precision temperature control system
- Exchangeable nozzles
### Cooling
- JARVIS Airpath ([cooling unit](https://www.qitech.de/en/industries))
- Horizontal tower fan (budget option)
### Winding
- JARVIS Winder ([automated system](https://www.qitech.de/en/industries))
- Filament pull unit
- Filament guider mechanism
- Tension-controlled spool axis

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---
title: Run a workshop on an event
slug: run-a-workshop-on-an-event
description: An essential aspect of addressing plastic pollution involves demonstrating the process in person. The following introduction provides a concise overview of the key considerations we focus on before initiating a public workshop.
tags: ["melting","collection"]
category: Guides
difficulty: Medium
time: 1-2 weeks
keywords: plastic pollution, workshop demonstration, mobile plastic workshop, injection machine, bicycle shredder, mold cycle time, workshop preparation, team collaboration, plastic recycling, promotional strategies
location: Dresden, Germany
---
# Run a workshop on an event
![Run a workshop on an event](190614-16_Altonale_VisionAir42.JPG)
An essential aspect of addressing plastic pollution involves demonstrating the process in person. The following introduction provides a concise overview of the key considerations we focus on before initiating a public workshop.
User Location: Dresden, Germany
## Steps
### Step 1: Prepare your machines
Before organizing workshops, consider the type of machine you plan to use. What kind of workshop are you conducting? How many participants will there be, and how much time is available?
Ensure all machines used publicly are safeguarded against any negligence. For optimal performance, verify that everything is clean and functioning properly, and consider having spare parts on hand.
![Prepare your machines 1 - Elleke_Precious Plastic.jpg](./Prepare_your_machines_1_-_Elleke_Precious_Plastic.jpg)
![Prepare your machines 2 - Elleke_Precious Plastic.jpg](./Prepare_your_machines_2_-_Elleke_Precious_Plastic.jpg)
![Prepare your machines 3 - Elleke_Precious Plastic.jpg](./Prepare_your_machines_3_-_Elleke_Precious_Plastic.jpg)
### Step 2: Prepare your moulds
Just as you rely on your machines, your molds must also be dependable. Molds should have a swift cycle time to allow more people to produce items efficiently.
Consider the following:
- Quick release system for rapid opening and closing of molds
- Small injection volume (efficiently converted)
- Easy product demolding
![Prepare your moulds 1 - Neja Hrovat_Konglomerat eV.jpg](./Prepare_your_moulds_1_-_Neja_Hrovat_Konglomerat_eV.jpg)
### Step 3: Prepare your equipment
You are preparing to leave your workshop and require everything necessary for operating a mobile plastic workshop efficiently. The following list, inspired by a source from Germany, may assist you:
- Injection machine and bicycle shredder
- Maintenance tools
- Product counter
- Electrical equipment (including power cable, distributor, and lighting)
- Molds
- Shredded plastic
- Clean, unprocessed plastic
- Sample materials for demonstration
- Informational materials such as flyers and posters
- First aid kit
- Camera
- Straps, tape, and ropes
- Tub and cleaning supplies for washing plastic
![Equipment 1 - Konglomerat eV.jpg](./Equipment_1_-_Konglomerat_eV.jpg)
![Equipment 2 - Konglomerat eV.jpg](./Equipment_2_-_Konglomerat_eV.jpg)
### Step 4: Prepare your materials
For your workshop, ensure you have shredded plastic and some clean plastic ready for shredding. It's wise to maintain a reserve in case the shredder malfunctions and your supply of granules runs low. Be prepared!
![Prepare your materials 1 - Neja Hrovat_Konglomerat eV.jpg](./Prepare_your_materials_1_-_Neja_Hrovat_Konglomerat_eV.jpg)
![Prepare your materials 2 - Neja Hrovat_Konglomerat eV.jpg](./Prepare_your_materials_2_-_Neja_Hrovat_Konglomerat_eV.jpg)
### Step 5: Prepare samples
Having a variety of material and product samples is beneficial for inspiring individuals and assisting them in understanding the potential of working with plastic. You can utilize your own products or acquire additional samples to showcase the creations of other workshops worldwide. Present the products in an aesthetically pleasing manner.
![Samples - Löhrer_Konglomerat eV.jpg](./Samples_-_Lohrer_Konglomerat_eV.jpg)
### Step 6: Prepare your message
Consider the following questions as you prepare:
- What is the purpose of this workshop?
- What knowledge and experience do you wish to impart to others?
- What are your areas of expertise?
![Prepare yourself - Konglomerat eV.JPG](./Prepare_yourself_-_Konglomerat_eV.JPG)
### Step 7: Prepare your team
Do not work alone; it is more enjoyable and relaxed to collaborate in a team.
We recommend having 3 to 4 supervisors when operating two machines, as there are always numerous inquiries.
What your team requires:
- Proficient operation of machines and molds
- Effective communication
- Unified mindset for consistent workshop quality
- Knowledge of commonly asked questions
Next step!
![Prepare your Team - Konglomerat eV.JPG](./Prepare_your_Team_-_Konglomerat_eV.JPG)
### Step 8: Typical questions asked at a workshop in public:
During the process, many individuals often have numerous inquiries. It is advisable to be prepared to respond to the following questions:
- What is your background?
- What is your objective?
- Can you be booked?
- What type of plastic can you process?
- Are the fumes harmful?
- What are the components of plastic?
- How can I transition my lifestyle to be more environmentally friendly?
![FAQ - Löhrer_Konglomerat eV.jpg](./FAQ_-_Lohrer_Konglomerat_eV.jpg)
### Step 9: Wanna get money?
Be aware you are engaging in a unique activity that few can offer. If you are invited to conduct a workshop, consider whether you wish to charge a fee. The amount is at your discretion and should reflect the conditions you encounter.
The following are possible cost items to consider:
- Transport
- Use of machinery, molds, and other tools
- Team fee
- Placement cost
- Coordination
- Organizational overhead
![Wanna get money - Precious Plastic Official.jpg](./Wanna_get_money_-_Precious_Plastic_Official.jpg)
### Step 10: Promote your workshop
To ensure maximum participation, it is crucial to inform potential attendees about your workshop.
Consider these promotional strategies:
- Share a story or post on social media.
- Create an event on relevant community platforms.
![Promote your Workshop.PNG](./Promote_your_Workshop.PNG)
### Step 11: Site-specific questions
As previously discussed, you are leaving your workshop.
To ensure the smooth operation of your mobile workshop, please address the following questions with the organizer:
- Power source: Is it adequate, and what is the distance to the plug?
- Do you require fresh water? Inquire about the nearest water tap.
- Weather conditions: Is the area protected from rain and well-ventilated with fresh air?
- How much space is available?
- What type of attendees is expected?
- What are the construction and dismantling times?
- Who is liable in case of any incidents?
![Site specific questions quer.jpg](./Site_specific_questions_quer.jpg)
### Step 12: Construction on site
Label all stations clearly and ensure sufficient space around the machines for visibility. Compare your setup with the processing course to ensure similarity.
Assemble your mobile workshop in advance and take a break before activities commence.
![Construction on side 1 - Hrovat_Konglomerat eV.jpg](./Construction_on_side_1_-_Hrovat_Konglomerat_eV.jpg)
### Step 13: Timing
It is advisable to test everything in advance with friends to ensure smooth operation. This approach provides a clearer understanding of areas that require improvement. Without practice, it is challenging to ascertain the number of people you can manage concurrently.
![Timing 1 - Löhrer_Konglomerat eV.jpg](./Timing_1_-_Lohrer_Konglomerat_eV.jpg)
![Timing 2 - Löhrer_Konglomerat eV.jpg](./Timing_2_-_Lohrer_Konglomerat_eV.jpg)
![Timing 3 - Löhrer_Konglomerat eV.jpg](./Timing_3_-_Lohrer_Konglomerat_eV.jpg)
### Step 14: Participation
Consider how to involve strangers in the process safely. Determine tasks they can perform without risking their safety or that of the machinery.
![Participation 2 - David Plas_BMBF.jpg](./Participation_2_-_David_Plas_BMBF.jpg)
![Participation 3 - Stadelhofer_Konglomerat eV.JPG](./Participation_3_-_Stadelhofer_Konglomerat_eV.JPG)
![Participation 1 - David Plas_BMBF.jpg](./Participation_1_-_David_Plas_BMBF.jpg)
### Step 15: Post processing
The final step involves thorough documentation.
How many individuals have you reached, and how many products did you produce? Were you able to establish valuable contacts, or did the press cover your activities?
Tracking your impact and learning from your experiences is essential. Additionally, ensure you collect all your photographs.
![Post processing quer.png](./Post_processing_quer.png)
## Resources
### Machinery & Equipment
- Injection machine
- Bicycle shredder
- Maintenance tools
- Product counter
- Electrical equipment (power cables, distributor, lighting)
### Molds & Production Tools
- Quick-release mold system
- Small injection volume molds
- Easy demolding design
- Spare parts
### Materials & Supplies
- Shredded plastic (with reserve)
- Clean unprocessed plastic
- Sample materials (for demonstrations)
- Informational materials (flyers, posters)
### Workshop Setup & Safety
- First aid kit
- Straps, tape, ropes
- Tub and cleaning supplies
- Camera (for documentation)
### Team Requirements
- 3-4 supervisors
- Machine/mold operation proficiency
- Effective communication skills
- Unified team mindset
- FAQ knowledge (e.g., plastic types, safety queries)
## References
## Articles
- [How to Run PLA Recycling Workshop](https://www.instructables.com/How-to-Run-PLA-Recycling-Workshop/)
- [Plastic Odyssey Educational Workshop](https://plasticodyssey.org/en/pedagogical-manufacturing-workshop/)
- [La Recyclerie Mobile Workshop](https://www.artexplora.org/en/festival/performance/atelier-la-recyclerie-mobile-sauvage-mediterranee-avec-la-collaboration-de-laure-prouvost)
## Books
- [Understanding Plastics Recycling](https://www.barnesandnoble.com/w/understanding-plastics-recycling-2e-natalie-rudolph/1137695178)
- [Plastics Injection Molding Guide](https://www.hudsonbooksellers.com/book/9781569906897)
## Papers
- [UNEP Pacific Workshop Report](https://www.unep.org/events/workshop/national-capacity-building-plastic-pollution-pacific-island-countries)
- [DOE Plastics Recycling Workshop](https://www.energy.gov/sites/prod/files/2020/07/f77/beto-plastics-wksp-rpt-final.pdf)
- [Community Plastic Recycling Thesis](https://digitalcollections.sit.edu/isp_collection/2797/)
- [Plastic Pollution Cost Analysis](https://ait.ac.th/event/workshop-on-costs-of-inaction-and-action-for-plastic-pollution/)
- [Python in Science Proceedings](https://proceedings.scipy.org/articles/proceedings-2015.pdf)
## YouTube
- [Paper Recycling Workshop Demo](https://www.youtube.com/watch?v=R5SBKty7ngs)
## Open-source Designs
- [Precious Plastic Starter Kits](https://www.preciousplastic.com/starterkits/showcase/mix)

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---
title: Run a workshop on an event
slug: run-a-workshop-on-an-event
description: An essential aspect of addressing plastic pollution involves demonstrating the process in person. The following introduction provides a concise overview of the key considerations we focus on before initiating a public workshop.
tags: ["melting","collection"]
category: Guides
difficulty: Medium
time: 1-2 weeks
location: Dresden, Germany
---
import { Image } from 'astro:assets'
# Run a workshop on an event
<Image src={import('./190614-16_Altonale_VisionAir42.JPG')} alt="Run a workshop on an event" />
An essential aspect of addressing plastic pollution involves demonstrating the process in person. The following introduction provides a concise overview of the key considerations we focus on before initiating a public workshop.
User Location: Dresden, Germany
## Steps
### Step 1: Prepare your machines
Before organizing workshops, consider the type of machine you plan to use. What kind of workshop are you conducting? How many participants will there be, and how much time is available?
Ensure all machines used publicly are safeguarded against any negligence. For optimal performance, verify that everything is clean and functioning properly, and consider having spare parts on hand.
<Image src={import('./Prepare_your_machines_1_-_Elleke_Precious_Plastic.jpg')} alt="Prepare your machines 1 - Elleke_Precious Plastic.jpg" />
<Image src={import('./Prepare_your_machines_2_-_Elleke_Precious_Plastic.jpg')} alt="Prepare your machines 2 - Elleke_Precious Plastic.jpg" />
<Image src={import('./Prepare_your_machines_3_-_Elleke_Precious_Plastic.jpg')} alt="Prepare your machines 3 - Elleke_Precious Plastic.jpg" />
### Step 2: Prepare your moulds
Just as you rely on your machines, your molds must also be dependable. Molds should have a swift cycle time to allow more people to produce items efficiently.
Consider the following:
- Quick release system for rapid opening and closing of molds
- Small injection volume (efficiently converted)
- Easy product demolding
<Image src={import('./Prepare_your_moulds_1_-_Neja_Hrovat_Konglomerat_eV.jpg')} alt="Prepare your moulds 1 - Neja Hrovat_Konglomerat eV.jpg" />
### Step 3: Prepare your equipment
You are preparing to leave your workshop and require everything necessary for operating a mobile plastic workshop efficiently. The following list, inspired by a source from Germany, may assist you:
- Injection machine and bicycle shredder
- Maintenance tools
- Product counter
- Electrical equipment (including power cable, distributor, and lighting)
- Molds
- Shredded plastic
- Clean, unprocessed plastic
- Sample materials for demonstration
- Informational materials such as flyers and posters
- First aid kit
- Camera
- Straps, tape, and ropes
- Tub and cleaning supplies for washing plastic
<Image src={import('./Equipment_1_-_Konglomerat_eV.jpg')} alt="Equipment 1 - Konglomerat eV.jpg" />
<Image src={import('./Equipment_2_-_Konglomerat_eV.jpg')} alt="Equipment 2 - Konglomerat eV.jpg" />
### Step 4: Prepare your materials
For your workshop, ensure you have shredded plastic and some clean plastic ready for shredding. It's wise to maintain a reserve in case the shredder malfunctions and your supply of granules runs low. Be prepared!
<Image src={import('./Prepare_your_materials_1_-_Neja_Hrovat_Konglomerat_eV.jpg')} alt="Prepare your materials 1 - Neja Hrovat_Konglomerat eV.jpg" />
<Image src={import('./Prepare_your_materials_2_-_Neja_Hrovat_Konglomerat_eV.jpg')} alt="Prepare your materials 2 - Neja Hrovat_Konglomerat eV.jpg" />
### Step 5: Prepare samples
Having a variety of material and product samples is beneficial for inspiring individuals and assisting them in understanding the potential of working with plastic. You can utilize your own products or acquire additional samples to showcase the creations of other workshops worldwide. Present the products in an aesthetically pleasing manner.
<Image src={import('./Samples_-_Lohrer_Konglomerat_eV.jpg')} alt="Samples - Löhrer_Konglomerat eV.jpg" />
### Step 6: Prepare your message
Consider the following questions as you prepare:
- What is the purpose of this workshop?
- What knowledge and experience do you wish to impart to others?
- What are your areas of expertise?
<Image src={import('./Prepare_yourself_-_Konglomerat_eV.JPG')} alt="Prepare yourself - Konglomerat eV.JPG" />
### Step 7: Prepare your team
Do not work alone; it is more enjoyable and relaxed to collaborate in a team.
We recommend having 3 to 4 supervisors when operating two machines, as there are always numerous inquiries.
What your team requires:
- Proficient operation of machines and molds
- Effective communication
- Unified mindset for consistent workshop quality
- Knowledge of commonly asked questions
Next step!
<Image src={import('./Prepare_your_Team_-_Konglomerat_eV.JPG')} alt="Prepare your Team - Konglomerat eV.JPG" />
### Step 8: Typical questions asked at a workshop in public:
During the process, many individuals often have numerous inquiries. It is advisable to be prepared to respond to the following questions:
- What is your background?
- What is your objective?
- Can you be booked?
- What type of plastic can you process?
- Are the fumes harmful?
- What are the components of plastic?
- How can I transition my lifestyle to be more environmentally friendly?
<Image src={import('./FAQ_-_Lohrer_Konglomerat_eV.jpg')} alt="FAQ - Löhrer_Konglomerat eV.jpg" />
### Step 9: Wanna get money?
Be aware you are engaging in a unique activity that few can offer. If you are invited to conduct a workshop, consider whether you wish to charge a fee. The amount is at your discretion and should reflect the conditions you encounter.
The following are possible cost items to consider:
- Transport
- Use of machinery, molds, and other tools
- Team fee
- Placement cost
- Coordination
- Organizational overhead
<Image src={import('./Wanna_get_money_-_Precious_Plastic_Official.jpg')} alt="Wanna get money - Precious Plastic Official.jpg" />
### Step 10: Promote your workshop
To ensure maximum participation, it is crucial to inform potential attendees about your workshop.
Consider these promotional strategies:
- Share a story or post on social media.
- Create an event on relevant community platforms.
<Image src={import('./Promote_your_Workshop.PNG')} alt="Promote your Workshop.PNG" />
### Step 11: Site-specific questions
As previously discussed, you are leaving your workshop.
To ensure the smooth operation of your mobile workshop, please address the following questions with the organizer:
- Power source: Is it adequate, and what is the distance to the plug?
- Do you require fresh water? Inquire about the nearest water tap.
- Weather conditions: Is the area protected from rain and well-ventilated with fresh air?
- How much space is available?
- What type of attendees is expected?
- What are the construction and dismantling times?
- Who is liable in case of any incidents?
<Image src={import('./Site_specific_questions_quer.jpg')} alt="Site specific questions quer.jpg" />
### Step 12: Construction on site
Label all stations clearly and ensure sufficient space around the machines for visibility. Compare your setup with the processing course to ensure similarity.
Assemble your mobile workshop in advance and take a break before activities commence.
<Image src={import('./Construction_on_side_1_-_Hrovat_Konglomerat_eV.jpg')} alt="Construction on side 1 - Hrovat_Konglomerat eV.jpg" />
### Step 13: Timing
It is advisable to test everything in advance with friends to ensure smooth operation. This approach provides a clearer understanding of areas that require improvement. Without practice, it is challenging to ascertain the number of people you can manage concurrently.
<Image src={import('./Timing_1_-_Lohrer_Konglomerat_eV.jpg')} alt="Timing 1 - Löhrer_Konglomerat eV.jpg" />
<Image src={import('./Timing_2_-_Lohrer_Konglomerat_eV.jpg')} alt="Timing 2 - Löhrer_Konglomerat eV.jpg" />
<Image src={import('./Timing_3_-_Lohrer_Konglomerat_eV.jpg')} alt="Timing 3 - Löhrer_Konglomerat eV.jpg" />
### Step 14: Participation
Consider how to involve strangers in the process safely. Determine tasks they can perform without risking their safety or that of the machinery.
<Image src={import('./Participation_2_-_David_Plas_BMBF.jpg')} alt="Participation 2 - David Plas_BMBF.jpg" />
<Image src={import('./Participation_3_-_Stadelhofer_Konglomerat_eV.JPG')} alt="Participation 3 - Stadelhofer_Konglomerat eV.JPG" />
<Image src={import('./Participation_1_-_David_Plas_BMBF.jpg')} alt="Participation 1 - David Plas_BMBF.jpg" />
### Step 15: Post processing
The final step involves thorough documentation.
How many individuals have you reached, and how many products did you produce? Were you able to establish valuable contacts, or did the press cover your activities?
Tracking your impact and learning from your experiences is essential. Additionally, ensure you collect all your photographs.
<Image src={import('./Post_processing_quer.png')} alt="Post processing quer.png" />

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## Articles
- [How to Run PLA Recycling Workshop](https://www.instructables.com/How-to-Run-PLA-Recycling-Workshop/)
- [Plastic Odyssey Educational Workshop](https://plasticodyssey.org/en/pedagogical-manufacturing-workshop/)
- [La Recyclerie Mobile Workshop](https://www.artexplora.org/en/festival/performance/atelier-la-recyclerie-mobile-sauvage-mediterranee-avec-la-collaboration-de-laure-prouvost)
## Books
- [Understanding Plastics Recycling](https://www.barnesandnoble.com/w/understanding-plastics-recycling-2e-natalie-rudolph/1137695178)
- [Plastics Injection Molding Guide](https://www.hudsonbooksellers.com/book/9781569906897)
## Papers
- [UNEP Pacific Workshop Report](https://www.unep.org/events/workshop/national-capacity-building-plastic-pollution-pacific-island-countries)
- [DOE Plastics Recycling Workshop](https://www.energy.gov/sites/prod/files/2020/07/f77/beto-plastics-wksp-rpt-final.pdf)
- [Community Plastic Recycling Thesis](https://digitalcollections.sit.edu/isp_collection/2797/)
- [Plastic Pollution Cost Analysis](https://ait.ac.th/event/workshop-on-costs-of-inaction-and-action-for-plastic-pollution/)
- [Python in Science Proceedings](https://proceedings.scipy.org/articles/proceedings-2015.pdf)
## YouTube
- [Paper Recycling Workshop Demo](https://www.youtube.com/watch?v=R5SBKty7ngs)
## Open-source Designs
- [Precious Plastic Starter Kits](https://www.preciousplastic.com/starterkits/showcase/mix)

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### Machinery & Equipment
- Injection machine
- Bicycle shredder
- Maintenance tools
- Product counter
- Electrical equipment (power cables, distributor, lighting)
### Molds & Production Tools
- Quick-release mold system
- Small injection volume molds
- Easy demolding design
- Spare parts
### Materials & Supplies
- Shredded plastic (with reserve)
- Clean unprocessed plastic
- Sample materials (for demonstrations)
- Informational materials (flyers, posters)
### Workshop Setup & Safety
- First aid kit
- Straps, tape, ropes
- Tub and cleaning supplies
- Camera (for documentation)
### Team Requirements
- 3-4 supervisors
- Machine/mold operation proficiency
- Effective communication skills
- Unified team mindset
- FAQ knowledge (e.g., plastic types, safety queries)

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---
title: XL Long bed 3D-printer conversion
slug: xl-long-bed-3d-printer-conversion
description: This tutorial explains how to install an extended bed on any compatible 3D printer. We utilized the extended bed to print wind turbine blades.
tags: ["extrusion"]
category: Guides
difficulty: Hard
time: < 1 week
keywords: 3D printer installation, extended bed tutorial, wind turbine blades printing, Anycubic I3 Mega S upgrade, Y-axis modification, heated bed construction, aluminum platform welding, fiberglass insulation, NiCr heating wire
location: Antwerpen, Belgium
---
# XL Long bed 3D-printer conversion
![XL Long bed 3D-printer conversion](197584567_823306731633606_2145684291652980688_n_3-181f6f3b22b.png)
This tutorial explains how to install an extended bed on any compatible 3D printer. We utilized the extended bed to print wind turbine blades.
User Location: Antwerpen, Belgium
## Steps
### Step 1: Gather all required parts
Necessary for this build:
Basics:
- A basic 3D-printer that allows modifying the firmware (such as an Anycubic I3 Mega S)
- A rigid table of 2 m (78.74 in) by 80 cm (31.5 in) or larger to accommodate all components
Movement system (Y-axis):
- 2 SBR25 1500 mm (59.06 in) rails
- 4 SBR25UU bearings with bearing holders
- 2.5 m (8.2 ft) glass fiber belt for 3D printers, often referred to as a GT2 belt with a 2 mm pitch
The heated bed:
- 5 aluminum profiles of 40 mm by 15 mm (1.57 in by 0.59 in)
- NiCr heating wire rated at 60 ohms and 3A, available in 5 or 10 m (16.4 or 32.8 ft) lengths
- Glass fiber sleeving to insulate the heating wire, resistant to at least 150 degrees Celsius (302 F)
- 16 threaded rods, 8 mm in diameter and 5 cm (1.97 in) in length, plus 32 nuts for securing both sides
- (Recommended) Glass fiber cloth measuring 50 cm by 50 cm (19.69 in by 19.69 in)
- Basic tools: a drill, screws, bolts, and nuts
![sbr25-18106554cb8.jpg](./sbr25-18106554cb8.jpg)
### Step 2: Assemble the bed
1. Weld the aluminum (aluminium) profiles to create a platform measuring 3.3 feet (1 meter) by 7.9 inches (20 centimeters). It is preferable to weld at the ends only, to prevent skewing or distortion during the welding process.
2. Drill holes for the bearing holders, ensuring they are positioned 3.3 feet (1 meter) apart.
3. Install the bearings approximately 2 inches (5 centimeters) from the bed.
4. Place the fiberglass (glassfiber) sleeve over the Nichrome (NiCr) heating wire and thread it through the hollow sections of the aluminum bed.
5. Optionally, place fiberglass cloth at the ends of each aluminum profile to retain air inside.
![IMG_20210324_173500_bed-1810657afe3.jpg](./IMG_20210324_173500_bed-1810657afe3.jpg)
### Step 3: Make the base: rails on a sturdy table!
Ensure the table is stable and immovable, as any instability significantly affects the print quality.
The rails may accumulate dust during installation; clean them thoroughly and apply some PTFE-oil before proceeding.
Review the technical drawing for proper installation of the remaining components before moving forward.
![IMG_20210324_173500-18106582b59.jpg](./IMG_20210324_173500-18106582b59.jpg)
![Modell Anycubic I3 Mega-1815ec84ed9.png](./Modell_Anycubic_I3_Mega-1815ec84ed9.png)
### Step 4: Assembling of the main parts
1. Drill holes for mounting the Y-axis. The screws for the stepper motor are quite small, so an adapter bracket was fabricated from leftover square aluminum for the pipe.
2. Position the stepper motor and pulley approximately 4.1 feet (1.25 meters) apart.
3. Acquire some sturdy L-hooks made of steel, stainless steel, or aluminum, and drill holes that align with the U-frame of the printer. By opting for sufficient height, a printable height of 10.2 inches (26 centimeters) was achieved, 2.4 inches (6 centimeters) higher than normal.
4. Extend the wire length of the Y-stepper as needed. Scrap 15 AWG (1.5mm²) electrical cable was utilized since a NEMA 17 stepper motor can handle up to 2A of current.
5. Secure the U-frame with the L-hooks on the table and lower the endstops for the Z-axis to capitalize on the added height.
6. Drill holes in the table to route the wires for the endstops and steppers. This allowed the use of all the original cables, except for the Y-axis.
### Step 5: Make a heated chamber
Employ your creativity to design a cover for the print area. Plastic foil may suffice to retain warm air, depending on ambient temperature. Favorable outcomes have also been achieved using cardboard and surplus Styropor, which is sufficiently robust to negate the need for a frame.
![285933284_595402385015141_3665024332632683864_n-181347e9f83.jpg](./285933284_595402385015141_3665024332632683864_n-181347e9f83.jpg)
![285471495_1936084283249380_3005529079324983930_n-181347ecc3f.jpg](./285471495_1936084283249380_3005529079324983930_n-181347ecc3f.jpg)
![285622700_5783098858366985_4106654552058906457_n-181347f02aa.jpg](./285622700_5783098858366985_4106654552058906457_n-181347f02aa.jpg)
### Step 6: Download Marlin 1.4.6 and modify the bed size.
You can find an adapted version specifically for the Anycubic I3 Mega S here: [github.com/davidramiro/Marlin-Ai3M](https://github.com/davidramiro/Marlin-Ai3M).
Higher versions contained a flawed manual bed leveling system, which is essential as it is easy for the bed not to be parallel to the table.
Install VSCode and open the code there. Modify the following properties in `configuration.h` to inform the printer of an increased bed size and higher build envelope:
a. Y_BED_SIZE: 999
b. MAX_Z_HEIGHT: 260
![vscode1-181346ef6df.png](./vscode1-181346ef6df.png)
### Step 7: Flash the modified firmware
Connect your printer mainboard using a USB cable. VScode will automatically connect to the correct serial port. Press the small arrow in the bottom left corner to initiate the upload process.
![vscode-181065d95c4.png](./vscode-181065d95c4.png)
### Step 8: Level the bed 'manually'
Certainly. Below is the revised text formatted in Markdown:
---
This procedure does not involve manually adjusting the four knobs on the underside of the print bed. Instead, execute the G29 S1 command, followed by G29 S2 until completion. The printer will calculate a grid of 5x5 points (1.97x1.97 inches) over the print bed and move to each position, allowing you to adjust the nozzle on the z-axis.
(The grid's point count can be modified in the firmware.)
For further details on the G29 command for Marlin, visit [marlinfw.org/docs/gcode/G029-mbl.html](https://marlinfw.org/docs/gcode/G029-mbl.html).
Upon completion of all 25 points, the printer will emit a sound and return the print head to the 0,0 position. Ensure the grid is saved with the M500 command. Before each print, initiate M420 S1 to enable mesh-bed leveling and retrieve the modified z-coordinates. It is advisable to include this in the custom g-code section of your slicer to ensure execution before each print.
---
![g29-1813475c01c.png](./g29-1813475c01c.png)
### Step 9: Test before you print big!
Printing large objects may require time to perfect. Adhesion issues might occur during the printing process. As the object increases in size, the likelihood of warping and detachment from the bed rises. Effective results have been achieved using rPET, PETG, and PLA with Formfutur's Magigoo as an adhesive. PET(G) adheres exceptionally well, and a base layer of PET(G) is used for printing ABS.
### Step 10: Profit
This extended bed conversion, for example, enables the printing of wind turbine blades, allowing you to construct your own wind turbines. Refer to our other tutorial for further details.
![284170163_326718269616463_2564227729431909493_n-1810a67e07f.jpg](./284170163_326718269616463_2564227729431909493_n-1810a67e07f.jpg)
![284410269_538285404469005_5504249321824877867_n (1)-181347fd79f.jpg](./284410269_538285404469005_5504249321824877867_n_1-181347fd79f.jpg)
## Resources
### Hardware
- Anycubic I3 Mega S 3D printer ([firmware modifiable](https://github.com/davidramiro/Marlin-Ai3M))
- Rigid table (2m × 80cm or larger)
- SBR25 1500mm linear rails (×2), SBR25UU bearings (×4), 2.5m GT2 belt
- Aluminum profiles (40×15mm, ×5), 60Ω NiCr heating wire, fiberglass sleeving (heat-resistant)
- 8mm threaded rods (×16, 5cm long), nuts (×32), optional 50×50cm fiberglass cloth
### Software
- [Visual Studio Code (VSCode)](https://code.visualstudio.com/) for firmware editing
- Customized Marlin firmware ([GitHub link](https://github.com/davidramiro/Marlin-Ai3M))
- Marlin G-code commands ([G29 reference](https://marlinfw.org/docs/gcode/G029-mbl.html))
### Tools & Accessories
- Drill, screws, bolts, and nuts for assembly
- Steel/stainless steel/aluminum L-hooks (for U-frame mounting)
- PTFE oil for rail lubrication
- Plastic foil/cardboard/Styrofoam for print area insulation
- 15 AWG electrical cable (for Y-axis stepper motor extension)
## References
## References
### Articles
- [Marlin G29 Command Documentation](https://marlinfw.org/docs/gcode/G029-mbl.html)
### Opensource Designs
- [Custom Marlin Firmware for Anycubic I3 Mega S](https://github.com/davidramiro/Marlin-Ai3M)

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