HeroX Challenge Research

Problem Defined

• It is known that plastic waste is a global problem that continues to not receive much attention. We continue to produce non-biodegradable plastic today.
• 300 million tons globally, 150 million tons as waste

Solution

• Large 3D Printer that can print plastic lumber from trash plastic
  • Extruder Head Temp: 300C | Build Plate Temp: 135C+ for Polycarbonate Standards
  • Frame built form Rebar Truss, ~$240 for a 10ft Frame
  • 7 Stepper Motors
  • High Temperature Build Chamber
    • Needed to protect electronics and stepper motors from damage due to high temperature
• Time to print a house?
  • 20lb's of plastic per day(24hr), using open source SuperVolcano Extruder head and SuperVolcano Heater Blocks.
    • Using a machine with multiple heads, 4-8 print heads. Looking to optimize to ~40lbs per head, per day
• Low cost shredder/filament maker for waste plastic
  • Using a treadmill motor for ~$50 at 30hp to 50 hp
• Cost to performance ratio?

Research and Potential Ideas

• Engineering Effort
  • 3D Printer Size
  • Building Printer Hardware
  • Further research into other materials to use for printing (Geo-Polymers)
• Revenue/Business Model
  • $100K Incentive
  • Precious Plastics Business Case Study
• Collaborative Effort
• City Engineering Code Reform and Certification
• Marketing/Sponsor/Outreach Efforts
  • Getting others to show up
• Sourcing Plastic Resources
  • Starting a Recycling Facility in a City/Town
  • Buy others waste for a price
  • Composition of the plastics

Questions/Alternatives

• Plastic forms for construction, an example would be rammed earth structures
• Chemical engineering before final plastic product?
• https://nefhousebuilder.com/insulated-concrete-forms/ - Research into insulated concrete forms
• Producing filament spools from the waste plastic?
• Risk of fire or high heat melting the structure?

Action Items

• Open Source High Temperature 3D Printer Industry Standards
• Perform cost-benefit analysis?