ACKNOWLEDGEMENT

We wish to express our sincere thanks to Dr. G CHANDRAMOHAN,

Principal, PSG Institute of Technology and Applied Research for his support in

carrying out the design and fabrication project as part of our curriculum.

We express our gratitude to Dr. N SARAVANAKUMAR, Professor and Head

of the Department, Department of Mechanical Engineering, PSG Institute of

Technology and Applied Research for his constant encouragement throughout

the project work.

We express our gratitude to Dr. D ELANGOVAN Review Committee

Member, Professor, Department of Mechanical Engineering, PSG Institute of

Technology and Applied Research and all the other technical and non- technical

staff of mechanical department.

We express our deep gratitude to Prof. J. NAGARJUN Assistant Professor,

Department of Mechanical Engineering, PSG Institute of Technology and

Applied Research who gave valuable guidance to design and fabricate the setup.

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TABLE OF CONTENTS
ACKNOWLEDGEMENT ................................................................................iii

TABLE OF CONTENTS .................................................................................. iv

ABSTRACT: .................................................................................................... vi

TABLE OF IMAGES ...................................................................................... vii

TABLE OF TABLES ...................................................................................... vii

LIST OF SYMBOLS ......................................................................................viii

CHAPTER 1 : INTRODUCTION ..................................................................... 1

1.1 Introduction To 3-D Printing ................................................................. 1

1.2 Applications .......................................................................................... 2

1.3 How Wastes Are Produced .................................................................... 2

1.4 Types Of Plastic Wastes ........................................................................ 3

1.5 Reasons For Recycling Plastics ............................................................. 4

CHAPTER 2 : LITERATURE REVIEW ........................................................... 6

CHAPTER 3 : PROJECT OBJECTIVES AND METHODOLOGY .................. 8

3.1 Objectives ................................................................................................ 8

3.2 Methodology ............................................................................................ 9

CHAPTER 4 : DESIGN AND MODEL ......................................................... 10

4.1 Why FDM Prints Recycler Was Chosen ................................................ 10

4.2 Introduction To FDM Prints Recycler .................................................... 11

4.3 Selection of FDM Prints Recycler .......................................................... 12

4.4 Parts Required For FDM Prints Recycler ............................................... 12

4.4.1 Shaft ................................................................................................. 12

4.4.2 Blades ............................................................................................... 15

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 4.4.3 Gears................................................................................................. 16

4.4.4 Bearing ............................................................................................. 19

4.4.5 Spacer ............................................................................................... 20

4.4.6 Shredding Chamber .......................................................................... 21

4.4.7 Outer Casing ..................................................................................... 21

4.4.8 Motor ................................................................................................ 23

4.5 CAD Models for FDM prints recycler parts .......................................... 23

CHAPTER 5 : FABRICATION AND TESTING ........................................... 27

5.1 Laser Cutting Of Blades And Spacer...................................................... 27

5.2 Turning And Threading Of Shaft ........................................................... 27

5.3 Milling Of Casing .................................................................................. 28

5.4 Welding Of Plates .................................................................................. 29

5.5 Hand Cranking Setup ............................................................................. 29

CHAPTER 6 : COST ESTIMATION .............................................................. 31

CHAPTER 7 : TESTING AND PERFORMANCE ......................................... 32

CHAPTER 8 : CONCLUSION AND FUTURE SCOPE ................................ 33

REFERENCES ................................................................................................ 34

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 ABSTRACT
The project focuses on creating an effective way to recycle and reuse the waste

that is formed by the constant use of 3-D printing. 3-D printing is indeed an

effective way to print prototypes and models without the requirement for any

form of tooling other than a 3-D printer. Eventhough it has been proven to be a

very useful process and has seen a drastic growth in the past years, it generates

enormous amount of waste. So, in this Technical Design Report underlies the

process went through in-order to making an easy and efficient recycling

process. The first step of the recycling process is the conversion of the waste

into a form which can be further recycled by shredding into chips. The chips

can be then converted into pellets which can be again 3-D printed after

extrusion. The extruded filament can be used to make 3-D printed prototype

again easily. Various parts required for assembly of the FDM prints recycler

like blades, shaft, spacer and casing were designed using CAD modeling

software. The deigned parts were fabricated by providing correct tolerances and

dimensions, using various manufacturing processes like laser cutting, milling,

turning, welding, threading etc. The fabricated parts were assembled and this

resulted in the creation of an effective way of recycling the waste. The FDM

prints recycler was then tested by installing a hand cranking mechanism inorder

to rotate the shaft with required torque to 3-D printed waste which was collected

and the project was completed.

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 TABLE OF IMAGES
Figure 1 : 2-D drafting of shaft ........................................................................ 14
Figure 2 : 2-D drafting of blades ...................................................................... 16
Figure 3 : Bearing cross-section ...................................................................... 19
Figure 4 : 2-D drafting of spacer ...................................................................... 20
Figure 5 : 2-D drafting of front plate ................................................................ 22
Figure 6 : 2-D drafting of side plates................................................................ 22
Figure 7 : CAD model for Blade ...................................................................... 23
Figure 8 : CAD model for Spacer .................................................................... 24
Figure 9 : CAD model for Shaft ....................................................................... 24
Figure 10 : CAD model for Front Plate ............................................................ 25
Figure 11 : CAD model for Side Plate ............................................................. 25
Figure 12 : Final CAD Assembly ..................................................................... 26
Figure 13 : Exploded view of FDM prints recycler .......................................... 26
Figure 14: Machined Shaft ............................................................................... 28
Figure 15: Plates after Milling ......................................................................... 28
Figure 16 : Hand Cranking Setup ..................................................................... 29
Figure 17 : Assembly of Shredder .................................................................... 30
Figure 18 : Size of pellets obtained .................................................................. 32

TABLE OF TABLES
Table 1 : Bearing Specifications ...................................................................... 19
Table 2 : Cost Estimation Table ....................................................................... 31

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 LIST OF SYMBOLS
F Force N
T Torque Nmm
R Radius of the blade mm
A Area mm2
d Diameter of the shaft mm
𝜏 Shear force N/mm2
𝜎 , Tensile strength of plastic N/mm2
P Power W

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