Experiments

3D PRINTING WITH POST INDUSTRIAL RECYCLABLE MATERIAL

Bulgaria, North Central Region of Bulgaria

Research and Development and Innovation Consortium, 3D Creativity and New Products Rapid Prototyping Lab (3DCLab)

Experiment objective

The main objective of the experiment is to integrate a 3D printer in the flexible tube manufacture accelerating the uptake of advance digital technologies to manufacture new products from Post Industrial Recyclable Material (PIRM) for achieving zero waste manufacture. The specific objective is to develop a new approach for new technological and metrology fixtures to be created by digital technologies (3D printer) and to design and demonstrate new products prototypes, using PIRM.

This innovative experiment is aligned with the DIH-World open call objectives as it aims integration of digital technologies (3D printer) in the manufacturing process to design and manufacture new products from industrial plastic material waste. The experiment combines the knowledge of a DIH and its technological experience with the desire of a mid-size company, manufacturing laminated tubes to implement digital technologies to achieve Circular economy principles in its manufacturing process creating and making new products from Post Industrial Recyclable Material (PIRM).

Challenges

The main challenge for the current production process is the question how to manage the wastage which is enough clean and homogenous and is it possible the company to make new high-tech products from this wastage? At present the company pays to a waste collecting firm to deposit it and the company loses money. How the wastage can be used for creating and manufacture of new products for different issues – for example, for printing of spare parts for the machines the company uses for the main production, for grippers for automation and for new transportation packaging?

Meanwhile there are other challenges as: there is a 3D printing knowledge gap in the company. The company managers want to infiltrate the 3D printing in the production process but there aren’t employees who have background to design, perform and operate the machine. Another challenge is that 3D printing isn’t standardized. The company may face difficulties stating with certainty that the products produced via 3D printing are of consistent quality, strength and reliability furthermore when it is known that they are produced from PIRM. Additive manufacturing complicates intellectual property. Since additive manufacturing designs can be printed by anyone at any time, it changes the way we see value – shifting the value from the object itself to its design. At present the company cannot solve these issues and needs the competence of the DIH.

  • Adopt 3D printing technology to make new high-tech products from PIRM;
  • Fill the 3D printing knowledge gap in the company;

Achieve consistent quality, strength and reliability of the 3D printed products.

Implementation Solution

The proposed solution is to use the created waste implementing new way of processing PIRM by adding a high tech digital process manufacturing high added value new products. The company can use directly plastic flakes or to preliminary process the waste industrial material to re-granules or further – to filament or powder. After these types of material processes the PIRM is used in a 3D printer for manufacture of new technological and metrology fixtures for robotization and new products prototypes.