Direct pellet extruder developed for LEDC - 3D print with recycled materials

The thesis is to develop a 3D printer that easily and conveniently can print with recycled plastic such as PET bottles, plastic packaging and much more. The printer will be designed according to the needs of a developing country. The idea is not to create an additive manufacturing factory but an effective manufacturing tool for the locals in the less developed parts of the country. The printer can be used to manufacture souvenirs, spare parts, kitchen supplies and much more and at the same time reduce the plastic waste in less economically developed countries (LEDC). Most Fused Deposition Modeling (FDM) printers use filament thread as a builder material. Manufacturing filament is complicated, expensive and energy consuming. Developing a 3D-printer that uses granulate/pellets/flakes will eliminate that process and will make it easier to use recycled plastics. All the parts of the machine are easy to repair and it is simple to change spare parts. Practically this means that all the components are easy to find in LEDC or can be printed using the same printer. Three prototypes were built and the last prototypes proved that fairly complicated models could be printed even if it was not performing ideally. The optimal settings was a printing temperature of 265 C, a print speed of 20mm/s, 0,6mm layer height and fan cooled.Popular science summary 3D-printing with recycled plastics Plastic consumption has increased twentyfold in the last half-century and is expected to double the next 20 years. This increase leads to pollution and intoxication of our oceans and environment. 95% of the value of plastic materials goes to waste and an alarming 32% escapes into the our oceans and other ecosystems. The people mostly affected by this is not the main consumer but the people living in developing countries. To this day there are about four billion people with an average daily salary of 4 USD (34SEK). These people are in the base of the world economy called “base of the pyramid” (BoP). The income varies and is very unpredictable. Many of these people have low or no formal education and have limited communication and distribution channels. Developing a 3D printer that easily and conveniently can print with recycled plastic such as PET bottles and plastic packaging will encourage the locals to recycle and find a value in the waste plastic. The printer will be designed according to the needs of a developing country. The idea is not to create an additive manufacturing factory but an effective manufacturing tool for the locals in the less developed parts of the country. The printer can be used to print souvenirs, spare parts, kitchen supplies and much more and at the same time reduce the plastic waste in LEDC. Most Fused Deposition Modeling (FDM) printers use filament thread as a builder material. Manufacturing filament is complicated, expensive and energy consuming. Developing a 3D-printer that uses granulate/pellets/flakes will eliminate that process and will make it easier to use recycled plastics. All the parts of the machine are very easy to repair and it is simple to change spare parts. Practically this means that all the components are easy to find in LEDC or can be printed using the same printer. Three prototypes were built and the last prototype proved that fairly complicated models could be printed. This printer could help reduce plastic waste and at the same time encourage entrepreneurship in the base of the pyramid