Using the Shredder V2.1 to Recycle 3D prints into Filament - Research

Using the Shredder V2.1 to Recycle 3D prints into Filament

thenextlayer

Started 9mo. Edited 9mo.Started 10 months ago. Last edit 10 months ago.

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Hi All Jonathan here from The Next Layer. Over the last year, I've been adapting the Shredder 2.1to recycle 3d Prints into new filament. It's been a long and difficult journey, which I documented all of the ups and downs of in my 6 part (and counting) YouTube series (http://jle.vi/frs), but I wanted to share just the top learnings and conclusions for my build here, for others to benefit - as well as the issues I'm having. First, the final setup: -Precious Plastic Shredder 2.1 from PP Capi Spain -30:1 Worm Gear -90L ~3HP Motor -Lovejoy flexible couplers + adapter shank for worm gear. (This proved necessary after bending the driveshaft the first time due to sub-mm differences in height between the shredder and the gear box) Now, the modifications I've made to enable this to work: -5mm sieve. I've found that 4.5mm is too small, and 8mm is much too large. 5mm is the sweet spot for the extruder I'm using, the ArtMe, though I do still have to sieve the material. -High Powered Turbine fan at the top of the hopper to push hot air though. This might not be necessary once I resolve the rubbing/friction issues The Process: After a LOT of trial and error, I've happened upon a process that works: -Shred the material -Sieve the material in a 4.5 or 4mm 3D printed mesh pan. -DO NOT WASH THE MATERIAL IN WATER TO REMOVE DUST, OR YOU'LL INTRODUCE MOULD. -Run a powerful magnet through the material, extensively, the remove metal shredding etc. -Dry the filament in the MICROWAVE (only non-CF materials). Ideally 30 seconds on (high power), 5 minutes off. Transfer containers if the container gets hot. (The Microwave is the only thing I've found that can remove enough of the moisture. A normal oven doesn't do it, but I haven't tried a vacuum oven. Obviously anything that blows hot air around like a filament dryer or food dehydrator is a non-starter). -Extrude the filament in the ArtMe Extruder. Settings seem to depend on color and percentage of fresh filament. I usually extrude 85% recycled material, and for that, the ideal settings are 17.6-18RPM, 25 fan, 176 Degrees celsius. This results in filament that is MOSTLY consistent - 1.72 to 1.76, generally, which is enough for my uses. However, I've spoken to experts, and they've told me that an additional step of pelletizing and re-extruding would yield much more consistent results. Now, the issues I'm facing: I used the shredder for months, but it always generated heat from friction, the driveshaft finally snapped. I thought the friction (and the metal powder in my regrind) was from the knives against the shredder wall, but clearly, it was slowly eating away at the driveshaft. I have NO IDEA how this happened, and would love insights. I think that the driveshaft was mounted at an angle, in the way that the bearings couldn't compensate for, but I don't understand how that would damage. In the interim, I've ordered at 4140 Steel Shaft replacement. Thanks!

extrusionshredder

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1 Project as it stands

thenextlayer

Published 9mo.Published 10 months ago.

Here is a full cost breakdown of the parts I used - it's not 100% up-to-date, as I haven't added the new driveshaft and new sieve, because I assume others won't break them, if my research is successful 😅 https://jonathanalevi.com/fcb Here I the video series, if you'd like to follow along: https://jle.vi/frs Here are images of the broken driveshaft for your analysis:

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