Polystruder, a Los Angeles-based start-up, is introducing a new suite of machines that aims to revolutionize 3D printing and make it more sustainable. Their innovative approach involves a four-machine package that shreds 3D prints, melts the material, and forms it into new filaments. This process allows for recycling plastic waste at the source, preventing it from ending up in landfills.
According to Ali Sureyya Torun,
the founder of Polystruder, implementing their four-machine package and embracing recycling practices can significantly contribute to minimizing plastic waste and its environmental impact.
Torun estimates that shredding parts and recycling them into new filaments can reduce overall 3D printing plastic waste by at least 50%.
Cost and environmental benefits of the Polystruder
In addition to the environmental benefits, there are also cost savings associated with using Polystruder’s machines.
Depending on the quantity and type of plastic used
as well as the amount of waste generated, a manufacturer using expensive materials could experience cost savings three to five times cheaper than purchasing filament externally.
The savings for PLA might be anything from 40% to 70%.
Moreover, by manufacturing filament from raw bulk plastics, businesses can achieve even higher cost savings.
For instance, the cost of each kilogram of PLA can be as low as $5, resulting in significant long-term savings.
Polystruder GR Pro
The first machine in Polystruder’s suite is the Polystruder GR Pro, which serves as the plastic shredder component.
It features an “ultra-quiet” 300W brushless DC motor with a 90:1 gear ratio, capable of shredding virtually any plastic material,
including PC, ASA, nylon, TPU, and even some engineering-class materials like PEEK and PEI.
The GR Pro can also process post-consumer waste such as beverage bottles and composite-based materials like carbon fibre and wood, although the latter can reduce the blade’s lifespan.
The shredder has 19 double-sided stainless steel blades,
which shorten shredding times and lower maintenance expenses.
Once the plastic is shredded,
the shreds can be processed using the other three machines in the suite: the extruder (XR Pro), the cooler (CR Pro), and the spooler (SP Pro).
These machines recycle the material into filaments, which can be used in 3D printers that print with shreds or pellets. Torun recommends processing the materials at least twice to achieve a more granular pellet size suitable for pellet 3D printers.
The extruder unit can produce 1.5kg of filament per hour and offers an optional extruder module for engineering-grade materials, capable of reaching temperatures up to 450ºC. The filament cooler ensures even cooling, and the spooler neatly spools 2kg of material. It’s worth noting that Polystruder is revamping its filament maker machines from scratch.
Polystruder’s shredder is currently available for pre-order at $1,999.
The company plans to start taking pre-orders for the other three units in Q4, with estimated delivery in late Q1 2024. The four-unit system will be priced at approximately $4,500.
Universities with 3D printing facilities, print-on-demand services, and small to medium-sized businesses are among Polystruder’s target clients.
However, some possible clients are enthusiastic about buying recycled filament created from particular materials,
such as local rubbish or ocean plastic. Torun emphasizes that by recycling plastic waste and producing high-quality filament,
companies can contribute to the circular economy and offer recycled filament to the market, companies that manufacture and market recycled filament.
Providing solutions to toxic 3d waste
plastic waste and producing high-quality filament, they offer a sustainable approach that reduces plastic waste, saves costs, and contributes to the circular economy. With their user-friendly features and competitive pricing, these machines have the potential to make a significant impact on the 3D printing industry and encourage more sustainable practices.