FilaMolds
Aarav Patel
Background
Over the past few years, the 3D printing industry has
increased greatly; in 2018 it was reported that globally there
were 140,000 industrial units sold and 2 million customer
units sold as well (Overview, 2019). 3D printers use plastic
filament to make the prints, but prints can fail or supports are
needed that are eventually broken off and thrown away
when done, as more plastic is thrown away it increases the
amount of plastic pollution. At the end of last year, it was
calculated by 2020 there will be a 3D printing waste volume
of 8 million kilograms (Toor, 2019) or 17636980.97 pounds.
Currently, there are ways to recycle failed prints or plastic
waste from printers to create a new filament spool;
however, to do this, it is very expensive as the products
that do this are over $100 on average. The goal of this
project was to recycle filament plastic not only for people
who own 3D printers, but a way to recycle plastic so
anyone can benefit. To do this, a mold would have to be
created to properly melt extra plastic, this would help
reduce plastic waste and pollution as less would be
thrown away and instead recycled into a new material.
Objectives
• To recycle leftover filament and reduce plastic waste
• Create new product from the filament to allow new
objects to be created that are useful
Figure 3. Pouring the
mold
Figure 1. Getting measurements of mold
parts
Material and Methods Results continued Conclusion
Materials
●
•
Safety Goggles -The 2nd trial was more successful as the parts were mixed properly and Part A was stirred
● Nitrile gloves
before doing anything In conclusion, the experiment was successful as a new
● Mold Max 60 -After 24 hours, the mold was cured, the filament was put into the mold then into the oven.
● Gram scale -The oven was set to 420 F at first then changed to 450 F, after 27 minutes the filament
product was created from leftover filament shreds by
● Mixing sticks melted, 16 minutes to cool. Smoke was released from the mold in the oven and a burning melting it in a mold placed in an oven. The project failed
● 3 disposable containers odor was released as well.
● Box with flat bottom on the first try but that was due to not stirring Part A of
● Paper towels
● PLA Filament shreds the mold prior to mixing and due to inadequate mixing of
● Metal tray
● Aluminum Foil the two parts together. It did not properly cure because
Figure 2. Showing the set up including:
Method(s)
Scale, containers, and Parts A and B of the mold after 24 hours, the mold was still wet and did not have a
1. Gather materials rubbery feel, so the project had to be restarted. After
2. Get object being casted as mold and place in a box
3. Get 3 plastic containers to pour Part A and B of the mold fixing the mistakes, it properly cured and from here, the
4. Stir part A and shake part B before starting to create the mold.
5. Get a 100A:3B ratio in mass, weigh on gram scale filament was placed into it and properly melted.
6. Pour 100 g of A and 3 g of B, once poured, mix thoroughly for 3 minutes
7. Pour the mixed mold on top of the object • The project may not be continued, but if future scientists
8. Allow to cure for 24 hours at room temperature, 74 F were to continue it, the project can be improved by
9. After a day, check to make sure the mold is dry by checking if wet at the touch
10.Take mold out of box and place onto aluminum foil on a metal tray making a deeper mold and use more filament due to the
11. Preheat oven to 420-450 F
12. Place filament shreds into the mold to completely fill it final product feeling thin and having a slight bend to it.
13. Cut filament pieces into smaller parts if needed
14. Place in oven and periodically check until fully melted into liquid form • The project can be useful as many schools have leftover
15. Take out of oven, place somewhere to cool, test to make sure liquid has cooled with toothpick filament that is wasted due to schools now using 3D
16. Take the plastic out of the mold Figure 5. 2nd box with
17. New product has been created wrench for casting
Figure 6. Mold poured into
printers. If it is possible to create a stronger product,
box
leftover filament can be taken from schools and create
school supplies that can help replace old ones such as
Results
paper clips or other useful items.
The first test of creating the mold was unsuccessful as the mold
did not cure in 24 hours
-This was due to not properly mixing Part A of the mold before
mixing and not properly mixing the two parts together for the 3
minutes
Figure 7. Mold fully Figure 8. Filament put
References
cured into mold
3D Printing Overview. (2019, August 2). Federation Of American Scientists – Science for a safer,
more informed world. https://fas.org/sgp/crs/misc/R45852.pdf
Hall, S. (2020, October 9). Is 3D printing increasing the plastic pollution problem?
AZoCleantech.com. https://www.azocleantech.com/article.aspx?ArticleID=870
Mold Max™ 60 silicone mold rubber product information. (n.d.). Smooth-On,
Inc. https://www.smooth-on.com/products/mold-max
60/?data=eyJlbWJlZF9wbGF5ZXJfdmVyc2lvbiI6IDIuMCwgInBsYXllcl9sb2NhdGlvbiI6ICJ
odHRwczov%0AL3d3dy5zbW9vdGgtb24uY29tL3Byb2R1Y3RzL21vbGQtbWF4LTYwLyI
sICJhY2NvdW50X2tleSI6%0AIiIsICJtZWRpYV9pZCI6IiJ9
Toor, R. (2019, November 27). The 3D printing waste problem. Filamentive | Leading 3D Printer
Figure 4. First test of Filament Brand in UK. https://www.filamentive.com/the-3d-printing-waste-problem/
mold- failed Why didn't my mold rubber cure? (n.d.). Smooth-On, Inc. https://www.smooth-
on.com/support/faq/129/#:~:text=Often%2C%20when%20mold%20rubber%20does,to%
20room%20temperature%20before%20use
All photos taken by Aarav Patel
Figure 9. Filament Figure 10. Final
fully melted and product with
cooling cooled filament