B.

Tech Project Report

Title
Design and Fabriation of 3D Printed Waste Recycling Setup

Presented by
Priyansh (20BME032)
Aryan (20BME004)
Ojas (20BME026)
Under the supervision of
Dr. Sanjay Mohan
Assistant Professor
SCHOOL OF MECHANICAL ENGINEERING,
SHRI MATA VAISHNO DEVI UNIVERSITY,
KATRA
 CONTENTS

 Introduction

 Literature Review

 Research Gap

 Objectives of the Research

 Methodology

 Timeline
INTRODUCTION:3D Printing
• 3D printing is a process where a digital model created using computer-aided design
software (CAD) is turned into a physical three-dimensional object by adding material a
layer at a time.
• There are many methods of melting or softening the material to produce the layers. Whilst
the technology has been around for 30 years it’s only in the last 5 years, and the rise of
desktop 3D printers, that people have become aware of its game changing potential across
all industries.
• It is also known as additive manufacturing and is changing the way in which we
manufacture and create, but not just in industry.
• Innovative designs are being used to develop machine parts, prosthetic limbs, sustainable
housing and even 3D-printed medications
• It all starts with making a virtual design of the object you want to create. This virtual
design is made in a CAD (Computer Aided Design) file using a 3D modeling program (for
the creation of a totally new object) or with the use of a 3D scanner (to copy an existing
object). A 3D scanner makes a 3D digital copy of an object. There are also lots of online
file repositories where you can download existing 3D files that will help get you started.
• The 3D printing process turns an object into many, tiny little slices, then builds it from the
bottom-up, slice by slice. The layers then build up to form a solid object. The process of
building objects in this way is also referred to as Additive Manufacturing.
INTRODUCTION: Characteristics of 3D Printing

Layered Additive Manufacturing: 3D printing builds objects layer by layer,

adding material only where needed. This contrasts with subtractive
manufacturing, which involves cutting or shaping material from a larger block,
resulting in less material waste in 3D printing.

Design Freedom: 3D printing allows for complex and intricate geometric designs
that are often impossible or very expensive to achieve with traditional
manufacturing methods. This design freedom enables innovation and creativity in
product development.

Rapid Prototyping: 3D printing is widely used for rapid prototyping. It allows

designers and engineers to quickly create physical prototypes to test and validate
their designs before committing to large-scale production.
INTRODUCTION: Characteristics of 3D Printing

Customization and Personalization: One of the standout advantages of 3D

printing is its ability to produce customized and personalized products. This is
particularly valuable in industries like healthcare, where customized medical
implants and prosthetics can be tailored to individual patients.

Cost-Efficiency for Low-Volume Production: 3D printing can be cost-effective

for low to medium production runs, as there are no expensive molds or tooling
required. This is especially beneficial for small businesses and startups.

Reduced Material Waste: Since 3D printing is an additive process, it minimizes

material waste, making it more environmentally friendly compared to traditional
manufacturing processes.
INTRODUCTION:3D Printing Filaments
PLA (Polylactic Acid): PLA is one of the most popular 3D printing filaments due
to its ease of use and environmental friendliness. It's made from renewable
resources like cornstarch and is biodegradable.
ABS (Acrylonitrile Butadiene Styrene): ABS is known for its durability and
strength. It's commonly used for functional parts and is more impact-resistant
than PLA, but it can produce fumes during printing, so proper ventilation is
necessary.
PETG (Polyethylene Terephthalate Glycol): PETG is a versatile filament that
combines the strength of ABS with the ease of printing of PLA. It's known for its
durability, clarity, and resistance to moisture.
TPU (Thermoplastic Polyurethane): TPU is a flexible filament used for
producing objects that need to be bendable or have rubber-like properties. It's
commonly used for making phone cases, shoe soles, and other flexible parts.
Nylon: Nylon filaments are known for their strength, durability, and low friction
properties. They are often used for producing functional parts, gears, and
bearings.
INTRODUCTION:3D Polylactic Acid (PLA)

• In the realm of consumer 3D printing, polylactic acid (PLA) is king.

Although it’s often compared to ABS — arguably the next in line to
the throne — PLA is easily the most popular type of 3D printer
filament, and for good reason.
• 3D Printer Filament Properties: PLA
• Strength: Medium | Flexibility: Low | Durability: Medium
• Difficulty to use: Low
• Print temperature: 180 – 230 °C
• Print bed temperature: 20 – 70 °C (but not needed)
• Shrinkage/warping: Minimal
• Soluble: No
• Food safety: Refer to manufacturer guidelines
INTRODUCTION: Acrylonitrile butadiene styrene (ABS)
• Acrylonitrile butadiene styrene (ABS) is less popular than PLA for
everyday 3D printing. However, in terms of material properties, ABS
is actually moderately superior to PLA, despite being more difficult to
print – it’s prone to warping without a hot print bed and bed adhesive.
• Commonly used in injection molding, ABS is found in many
manufactured household and consumer goods, including LEGO
bricks and bicycle helmets.
• 3D Printer Filament Properties: ABS
• Strength: High | Flexibility: Medium | Durability: High
• Difficulty to use: Medium
• Print temperature: 210 – 250 °C
• Print bed temperature: 80 – 110 °C
• Shrinkage/warping: Considerable
• Soluble: In esters, ketones, and acetone
• Food safety: Not food safe
 LITERATURE REVIEW
Author Title Remarks
Bankole I. Net zero on 3D printing 3D printing, or additive manufacturing,
Oladapo filament recycling: A constructs objects by layering material, offering
et. al., sustainable analysis benefits like reduced waste and complex
geometries. As its popularity grows, there's a
rising need for raw materials for printing
filaments, prompting sustainability concerns.
Recycling 3D printing filament is a potential
solution, involving the collection, sorting, and
reprocessing of used material for new printing.
This study evaluates the environmental impact
of filament recycling and the feasibility of
achieving net-zero emissions in the 3D printing
industry.
 LITERATURE REVIEW
Author Title Remarks
Freddys R Beltrán Evaluation of the Recovered PLA wastes from various sources
et. al., Technical Viability of were cleaned and reprocessed into films
Distributed Mechanical through melt-extrusion and compression
Recycling of PLA 3D molding to mimic industrial processes. The
study examined the optical, structural,
Printing Wastes thermal, and crystallization characteristics of
these materials. Mechanical recycling
increased crystallinity and decreased intrinsic
viscosity, especially in blends of different 3D-
PLA wastes. These recycled films degraded
faster under composting conditions than the
original 3D-PLA filament due to shorter
polymer chains. Solid-state polymerization at
different temperatures improved the intrinsic
viscosity of recycled materials from a well-
known reference grade but had no significant
impact on those from different sources. This
study demonstrates the feasibility of
implementing distributed recycling programs
for 3D printing PLA products, especially when
using well-known PLA grades, resulting in
films with good overall performance.
 LITERATURE REVIEW
Author Title Remarks

Antonio A comparison between In this study, the researchers initially printed

Lanzotti mechanical properties of specimens using brand new PLA filament and
et. al., specimens 3D printed with tested their mechanical properties. They then
virgin and recycled PLA took these printed specimens, ground them into
small pieces, and re-extruded them into filament
using a DIY extruder. With this recycled filament,
they printed a new set of specimens and
analyzed their mechanical properties. The study
involved three recycling processes in total to
evaluate their impact on mechanical properties.
The results indicated that 3D printing with
recycled PLA filament could be a feasible and
viable option, suggesting the potential for
sustainable and cost-effective 3D printing
practices.
 LITERATURE REVIEW
Author Title Remarks

Xiaoyong Recycling and A cleaner production method for high-

Tian remanufacturing of 3D performance continuous carbon fiber reinforced
et. al., printed continuous carbon thermoplastic composites (CFRTPCs) has been
fiber reinforced PLA proposed. This method involves recycling and
remanufacturing of 3D printed continuous
composites carbon fiber reinforced (CFR) PLA composites.
The continuous carbon fiber and PLA matrix are
recycled in the form of PLA-impregnated carbon
fiber filament from 3D printed composite
components, and they are reused as raw
materials for further 3D printing processes. The
original printing trajectory is reversed, enabling a
100% recycling of the continuous fiber without
compromising mechanical properties. In fact, the
tensile performance of recycled carbon fiber
filaments was found to be even higher than that
of the originally printed composites. This
approach offers a more sustainable and efficient
way to produce high-performance CFRTPCs.
 LITERATURE REVIEW
Author Title Remarks

Eduardo Technical Evaluation of The significance of 3D printing is rapidly

Moreno Mechanical Recycling of increasing, exemplified by its role in addressing
et. al. PLA 3D Printing Wastes † the Covid-19 pandemic's critical supply
shortages. However, 3D printing also generates
substantial plastic waste, posing an
environmental concern. Therefore, managing
this waste is essential. Combining additive
manufacturing with distributed mechanical
recycling can contribute to a more circular
economy. This study aimed to characterize
poly(lactic acid) (PLA) wastes from 3D printing
processes and assess how their heterogeneity
affects the technical feasibility of mechanical
recycling. Two types of PLA 3D printing wastes
were examined: one from a well-known PLA
grade and another from a mix of PLA 3D printing
residues from an association of coronamakers in
Madrid. Recycled material from the well-known
PLA grade showed properties similar to unused
material, but recycled material from mixed PLA
waste exhibited lower viscosity, higher
crystallization ability, and reduced transparency.
These findings underscore the importance of
 LITERATURE REVIEW
Author Title Remarks

Katarzyna 3D printing filament as a In recent times, plastic recycling has become a

Mikula second life of waste crucial environmental concern due to the
Et al plastics—a review widespread use of polymer materials in daily life
and industry, resulting in plastic waste
accumulation. Recycling offers a way to
repurpose these materials, addressing waste
management issues.
The growing 3D printing industry presents an
opportunity to produce printable filaments from
recycled plastics. This review paper explores the
viability of using recycled polymers for 3D printer
filaments, offering an alternative to centralized
plastic collection. It also examines the impact of
processing on the properties of recycled
thermoplastics, discusses commercially available
recycled filaments, and introduces devices for
DIY filament production using plastic waste.
.
 LITERATURE REVIEW
Author Title Remarks

Muyiwa The potential of converting Additive manufacturing (3D printing) can

Oyinlola plastic waste to 3D printed
products in Sub-Saharan
Africa
transform low-income societies with
underdeveloped infrastructure and inadequate
manufacturing capabilities. However, uptake in
sub-Saharan Africa is still very low. This study
adopted a transdisciplinary approach which
included critical synthesis of the extant literature,
laboratory experiment and a cross sectional
engagement with stakeholders, to examine the
potential of converting plastic waste to 3D printed
products in sub-Saharan Africa. The study showed
that while several extruders have been developed
in the last decade, there are still many challenges
some of which include difficulty to produce
filaments with consistent diameter, degraded
mechanical properties and health hazards from
emissions during extrusion. Furthermore, it was
observed that communities across sub-Saharan
Africa are interested in 3D printing but do not
have sufficient understanding. The study
highlights the need for building local capacity to
 LITERATURE REVIEW
Author Title Remarks

Alaeddine Development of 3D This study examines the potential of 3D printing

Oussai Printing Raw Materials to benefit low-income communities in sub-
from Plastic Waste. A Case Saharan Africa, despite its limited adoption in
Study on Recycled the region. Employing a transdisciplinary
approach that combines literature review, lab
Polyethylene Terephthalate experiments, and stakeholder engagement, the
research investigates the conversion of plastic
waste into 3D printed products.
The study identifies ongoing challenges, such as
difficulties in ensuring consistent filament
diameters, reduced mechanical properties of
printed items, and health concerns related to
extrusion emissions. Furthermore, it highlights a
strong interest in 3D printing within sub-Saharan
African communities but notes a lack of
sufficient knowledge.
In summary, the study emphasizes the need to
cultivate local expertise for the development,
operation, and maintenance of 3D printing
technologies in the region, underlining the
importance of education and skill-building for
unlocking 3D printing's potential.
 LITERATURE REVIEW
Author Title Remarks

Saltanat Manufacture and his paper explores the properties of 3D-printe

Bergaliyeva Characterization of polylactic acid (PLA) blends, combining varyin
Polylactic Acid Filaments amounts of virgin and recycled PLA material.
Recycled from Real Waste recycled material, derived from real waste, w
shredded and size-sorted without washing. D
for 3D Printing bone-shaped specimens were 3D printed from
filaments made using a single screw extruder.
The study found that adding recycled PLA deb
to the raw material did not significantly impac
the thermal stability of the 3D-printed sample
Both virgin and recycled PLA degraded at simi
temperatures. Increasing recycled content led
reduced crystallinity, as revealed by differenti
scanning calorimetry. Scanning electron
microscopy showed that pure PLA specimens
had a more uniform structure, while PLA blen
exhibited a more diverse one.
Tensile strength increased with higher
proportions of recycled material, ranging from
44.20 ± 2.18 MPa for pure PLA to 52.61 ± 2.28
MPa for the blend with the most recycled PLA
content. However, the study highlights that th
mechanical properties and fundamental
 RESEARCH GAP
The material of 3D printed filaments are not biodegradable at normal condition.

They decompose at a specific conditions in a lab environment, however

recycling them again into filament is much more possible.

Stages of waste

Thus there is need to design and fabricate a 3D Printed Waste Recycling

machine.
 METHODOLOGY

Study of different types of waste

Raw Layout of the Recycling

Machine

Mechanical Design of the different

components

Fabrication of different
components

Assembly of the Components

Working Model
 TIMELINE

7 August to 25 August Brains Storming of Ideas

26 August to 9 September Litrature Review

10 September to Till Now Desiging In Process

Design Illustration
Compression Screw
Working compression screw
Thank You