AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

MEFFILAMENT
Chapter 1

INTRODUCTION
Nowadays, 3D printing is a very popular method of rapid prototyping, which creates fully
usable models and complete projects. In our university of technology, we are using 3D
printing in every project, a lot of parts are small, but we need them to be durable, for
example, gear, clutch, motor mounting. Researchers are also exploring means of improving
the mechanical properties of prints to create composite filaments.

People will recycle if they can make money doing so. In places where cash is offered for
cans and bottles, metal and glass recycling has been a great success. Sadly, the incentives
have been weaker for recycling plastic. As of 2015, only 9% of plastic waste is recycled.
The rest pollutes landfills or the environment.
But now, several technologies have matured that allow people to recycle waste plastic
directly by 3D-printing it into valuable products, at a fraction of their normal cost.
People are using their own recycled plastic to make decorations and gifts, home and garden
products, accessories and shoes, toys and games, sporting goods and gadgets from millions
of free designs.
The possibilities that 3D gives us are irreversible, very low cost, quick step of conversion of
computer model into real object, and also, 3D printing allows us to create elements that are
not accessible by other means. During prototyping, a lot of material and parts are left as
useless in the form of failed prints, poorly designed models, or poor print optimization.
Making a perfectly satisfying portion leaves a lot of unused material in the bin.
We are living in an era where tons of waste is generated, including PET bottles in large
quantities so that we can combine this waste process with our passion and work. Like other
researchers, we aim to reduce our environmental impact and look for means to reuse the
material for 3D printing.
This article is about a simple device that allows us to convert unused PET bottles into 3D
printer filament. There are many materials available in the market, also PET filament, which
is very durable, chemical and temperature resistant, flexible and easy to print.

Filament extrusion machines are typically available for industrial use, capable of producing
filaments.

Dept. of ECE 1 SGBIT, Belagavi

 AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT

Chapter 2
LITERATURE SURVEY
1. Prof. Vikrant Dhopte, Pranay Khapre, Onkar Bhagat, Himanshu Warhokar has
proposed that different types of plastics produce different types of filaments. For
example, high-density polyethylene is relatively easy to convert into filament, but difficult
to print with, as it shrinks more than other plastics when cooled. PET, on the other hand,
prints well but is brittle,making it difficult to spool as a filament.

2. Hamsuzzaman Rasell & JoySarkar It is assumed that there are approximately 165
million tons of plastics in the ocean which could be more than the weight of fisheries
by 2050. As there requires only some extra arrangement as regular the environment.
Only mixing the concept of plastic bottle melt filtration and fiber formation is required. By
recycling we could make a wide range of polyester fabric and at the same time we could
make a saferworld.

3. Igor Tylman and Kazimierz Dzierże Samples of an ordinary PETG filament from
market and BPET filament were created. Transparency of both filaments was
essential to make observations using an available microscope .As we can see in the
figure below, the internal structure of the PETG filament is uniform and external
structure without distortion. Unlike the previous filament, this one has visible defects
in the internal structure, most likely, it is an empty space created in the processing
process

4. B. N. Turner, R. Strong, and S. A. Gold, “A review of melt extrusion additive

manufacturing processes: I. Process design and modeling,” Rapid Prototyping
Journal, vol. 20,no. 3, pp. 192–204, Apr. 2014.

5. R. Elhajjar and T. Gill, Studies into Additive Manufacturing for InSpace

Manufacturing ,Warrendale, PA: SAE International, 2016.

6. K. Dzierzeket al., “Design and static tests of an all-terrain suspension system for
electric wheelchairs,” in Proc. 2018 International Conference BIOMDLORE,
Bialystok, 2018, pp. 1–5.

Dept. of ECE 2 SGBIT, Belagavi

AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
7.
MEFFILAMENT

8. M. Rećko, J. Tołstoj-Sienkiewicz, and P. Turycz, “Versatile soil sampling

system capable of collecting, transporting, storing and preliminary onboard analysis
for mars rover analogue,” Solid State Phenomena, vol. 260, pp. 59–65, July 2017.

9. P. Tomaszuk, A. Lukowska, M. Recko, K. Dzierzek, and P. Straszynski,

“Active wheel speed control to avoid lifting the swingarms in rocker- bogie
suspension,” in Proc. 2019 International Young Engineers Forum (YEF-ECE),
Costa da Caparica, Portugal, 2019, pp. 36–39.

10. P. Tomaszuk, A. Lukowska, M. Rećko, and K. Dzierzek, “Integrated drive

system of robotic arm joint used in a mobile robot,” in Proc. 2018 23rd
International Conference on Methods & Models in Automation & Robotics
(MMAR), Miedzyzdroje, 2018, pp. 509–514.

11. Alvaro Goyanes et al (2014), their project is to build an extrusion machine that
creates 3Dprinter filament from water bottles, these water bottles square measure
typically polyethylene terephthalate (PET) materials that square measure taken as
intake for creating filament.

12. Mark D Grooms (2016), their project is to develop a 3d printer filament extruder
at low value with the assistance of the materials and elements that they got the
scraps and that they mentioned to use simple materials to complete the whole
product.

13. Antonim Durna (2014), this text deals with the modification of the nozzle and its
entire assembly with a hot finish, in order that it had been not necessary to use a
Teflon insertion and to succeed in the most temperature of the nozzle.

14. Kreiger et al (2014), here they mentioned the various sorts of materials that may be
used for 3D printer applications and their properties of the materials supported
melting temperature and set temperature.

15. Meera Mohan et al (2017), during this project they need research and studies
concerning completely different sorts of temperature sensors that may be utilized in
different applications to live the specified temperatures.

Dept. of ECE 3 SGBIT, Belagavi

 AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT
2.1 Outcome of Literature Survey
The most popular way to create filament from plastic bottles or plastic waste is
creating granules and then using those for processing, this is more complicated process
and the machine is much bigger, not that compact size like machine in this project.
Compared with another constructions machine build in this project is made of 70% from
3D printed parts which affects the low price of the device. Plastics are not susceptible to
biodegradation and their decom-position causes additional contamination of the
environment. Recycling was found to be the most advantageous method to valorize post-
consumer plastics that stays in line with a concept of circular economy. Degradation of
plastics lasts from 10 to 450 years. From the historical point of view, recycling has been
undertaken by the means of large centralized plants that produce commodities of low
value. This is related with high costs of transportation. 3D printing enables different
approaches. Desktop 3D printing makes it possible to produce
complicated plastic products at home instead of in factory. It is estimated that the value of
this sector will increase intensively the next years. The idea is that consumer can produce
goods
directly from his own used materials. This provides several savings: environmental and
buying commercial plastic goods and enables to close the loop of circular economy.
Also recently, during coronavirus crisis, we observe individual applications that are
possible for given needs. There are examples of 3D printing of, e.g., visors as a medical
cover that
protects eyes from coronavirus infection. By popularization of 3D printing, it is possible
to adjust production to temporary needs.

Dept. of ECE 4 SGBIT, Belagavi

 AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT
Chapter 3

PROBLEM STATEMENT AND OBJECTIVES

3.1.1 PROBLEM STATEMENT

As the plastic waste at the dump yards is increasing day by day and creating a big
environmental pollution resulting in many other problems. Keep this in mind this project is
about making a machine which converts PET bottles into printable filament which can be
used for 3D printing which not only gives second life to the bottle but also reduces the cost
of the filament to almost 10 times. Through this project we have also tried to optimize the
printing flow rate to compensate for the hollow tube.

3.1.2 OBJECTIVES

• To develop the abilities such as working in groups, sharing

responsibilities, initiative, perseverance.
• To make a device in an efficient and cost effective way.

• To make a device to reuse plastic waste.

• Reuse of plastic waste in 3D device manufacture to solve multiple

problems.
• To optimize the printing settings that can improve the quality of
the printed objects.

Dept. of ECE 5 SGBIT, Belagavi

 AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT
3.2 PROPOSED METHODOLOGY
As we have described the problem statement the project is the solution for all this
problem the project not only deals in reusing the plastic waste but also making of
filament which is 10 times cheaper with good printing results. As a part of the project
we have used and teste dall standard and inexpensive components. The block diagram
of the project is as shown in figure

Fig 3.1 Block diagram of proposed model

3.2.1 WORKING
As we have described the problem statement the project is the solution for all this
problem. This machine works with PET bottles and that shows some promise. This
machine works in a simple way. The Plastic bottles which are mostly of PET material
are cut into a long strip of certain width based on the wall thickness of the bottle.

Dept. of ECE 6 SGBIT, Belagavi

 AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT

Fig 3.2 Strip to tube formation

The strip is fed into the nozzle which is heated at a temperature of 250
degree centigrade (temperature below melting point of PET). The temperature is
maintained by the temperature sensor. The material is slowly extruded from the other
end of the nozzle in the form of a tube of 1.5mm diameter as shown in the figure 4.12.
Once a little bit of extruded tube comes out, it is then pulled and attached to the roller
which is rotated by a DC motor through 3d printed gears. The speed of the motor can
be controlled and set using an Arduino and potentiometer. From then on, the motor will
spin and pull the tube onto the roller as shown in figure 4.13. The idea is that people
should end up with a spool of PET filament that they can then print like any other
filament.

Fig 3.3 Roller and tube

Most 3D printer models do not have any kind of closed-loop feedback and do not know
how much plastic they are truly extruding. They only know how much filament they

Dept. of ECE 7 SGBIT, Belagavi

 AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT

push into the hot end, which they calculate by the length of the filament fed by the
extruder gear. But a length of filament is a three-dimensional cylinder, which means that
the calculated volume comes from the length and the diameter. If that diameter changes
or the filament isn’t perfectly round, the volume calculations will be wrong and the
printer will extrude more or less plastic than it intends to. Here not only the diameter is
consistent but the filament itself is a tube.

To minimize this issue by comparing the actual volume extruded vs the volume to be
extruded. This was done by extruding a tube of length of 150 mm and 1.5mm diameter
and was extruded through the 3d printer (ENDER 3) and the extruded material was then
weight don a weighing machine.

Volume of filament to be extruded, volume of filament actually extruding Length=

150mm, Weight= 0.2g, mass= 0.2g,Diameter= 1.75mm

Density= 1.397g/cc Volume= 0.361cc, Volume= mass/density= 0.143cc

As the material is under extruded the follow rate should be increased to equalize to
reduce the under extrusion issue.

Actual extruded volume is 0.143(100%)To be

extruded volume is 0.361cc (253%)

Therefore the flow rate should be increased to around 253% to get good results.

Dept. of ECE 8 SGBIT, Belagavi

AN INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT
MEFFILAMENT
3.5 ADVANTAGES, DISADVANTAGES & APPLICATIONS
3.5.1 ADVANTAGES
• Operation is easy.

• Cost effective.

• Implementation is easy.

• Reduce environment pollution

• Simple construction.

• Can replace expensive filaments

3.5.2 APPLICATIONS
1. Can be used as a filament for 3D printing Objects such as decorative or any hobby
based project.

2. It can be used to make components for sandcasting aka lost pla casting.

3. As it is low cost filaments can be done by investing low cost.

3.5.3 DISADVATAGES
1. Its difficult to clean a bottle.

2. The filament diameter is not consistent and PET doesn't have good layer adhesive
property.

3. Any dirt remaining in the filament can clog the printer nozzle.

4. Print quality is not up to the mark with this material.

Dept. of ECE 9 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

Chapter 4

CONCLUSION AND FUTURE SCOPE

4.1.1 CONCLUSION
We have taken up this project as a real challenge, as we were not
experienced in this field. We started our work on this project facing new
hurdles initially. The maneuverability of the device is quiet easy, the
handling and working is quite simple yet trying to solve one of the biggest
issue of plastic waste management, For commercial purposes one can
improve the accuracy and productivity of the device effectively by adding
more sensors as a feedback system to monitor the diameter of the tube.

4.1.2 FUTURE SCOPE

We feel the project that we have chosen has a good future scope in
Additive manufacturing. As it is low cost device so it has future scope
which industry can use as it is low cost and operation is easy .Therefore it
has constant diameter ,it can be accurate filament and can be used for 3D
printers for sandcasting akka lost pla casting that’s all about future scope

Dept. of ECE 10 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

4.2 References
[1] K. Dzierzeket al., “Design and static tests of an all-terrain suspension
system for electric wheelchairs,” in Proc. 2018 International Conference
BIOMDLORE, Bialystok, 2018, pp. 1–5.

[2] P. Tomaszuk, A. Lukowska, M. Recko, K. Dzierzek, and P.

Straszynski, “Active wheel speed control to avoid lifting the swingarms
in rocker-bogie suspension,” in Proc. 2019 International Young Engineers
Forum (YEF-ECE), Costa da Caparica, Portugal, 2019, pp.

[3] P. Tomaszuk, A. Lukowska, M. Rećko, and K. Dzierzek,

“Integrated drive system of robotic arm joint used in a mobile robot,” in
Proc. 2018 23rd International Conference on Methods & Models in
Automation & Robotics (MMAR), Miedzyzdroje, 2018, pp. 509–514.

[4] M. Rećko, J. Tołstoj-Sienkiewicz, and P. Turycz, “Versatile soil

sampling system capable of collecting, transporting, storing and
preliminary onboard analysis for mars rover analogue,” Solid State
Phenomena, vol. 260,pp. 59–65, July 2017.

[5] Alvaro Goyanes et al (2014), their project is to build an extrusion

machine that creates 3D printer filament from water bottles, these water
bottles square measure typically polyethylene terephthalate (PET)
materials that square measure taken as in take for creating filament.

[6] Meera Mohan et al (2017), during this project they need research and
studies concerning completely different sorts of temperature sensors that
may be utilized in different applications to live the specified temperatures.

[7] Kreiger et al (2014), here they mentioned the various sorts of materials
that may be used for 3D printer applications and their properties of the
materials supported melting temperature and set temperature.

Dept. of ECE 11 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

Dept. of ECE 12 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

Dept. of ECE 13 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

Dept. of ECE 14 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

Dept. of ECE 15 SGBIT, Belagavi

 INNOVATIVE WAY OF RECYCLING PET BOTTLES INTO 3D PRINTING FILAMENT

Dept. of ECE 16 SGBIT, Belagavi