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
  • Extruder Head Temp: 400C | Build Plate Temp: 135C+ | Build Chamber: 145C+ for PEAK Plastics Family Standards
  • High Temperature Build Chamber
    • Needed to protect electronics and stepper motors from damage due to high temperature
    • Carbon Fiber, Fiberglass for insulation
    • Heat shield plate moves with the nozzle. This must be twice the size of the chamber
• 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

Business Cases and Price Points

• Cost to performance ratio? Currently looking at ~$6K, almost 10x to a comparable printer with similar specs but larger build size capabilities looking at price alone
  • To reference another comparable industrial printer Extruder: Up to 480C | Build Plate: 250C | Chamber: 250C : miniFactory Ultra Price point is ~$54K
  • Using a treadmill motor for ~$50 at 30HP to 50HP
  • Frame built form Rebar Truss, ~$240 for a 10ft Frame
  • Build Chamber: ~$5K
  • 7 Stepper Motors at ~$50 per motor
  • Stepper Motors:
  • Controller:
  • Metal Hotend:

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
• Engineering the plastic before final 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?
• Using larger nozzles allows for higher tolerance

Action Items

• Open Source High Temperature 3D Printer Industry Standards
• Perform cost-benefit analysis?
• Create designs for Build Chamber and protect electronics/stepper motors
• "Rally the troops"
• How do we lower the cost to truly 10x the next comparable printer?
• Install OSE Workbench for CAD and dig in. OSE FreeCAD Workbenches
• Research some aspects of materials science to determine which types of waste plastic can blend together. Some waste plastic will not be used for various reasons

Sources

• PEEK/PEKK/PEI Material Reference from 3M
• PEEK/PEKK Material Reference
• Comparable 3D Printers