technologies

Article
Open Source Waste Plastic Granulator
Arvind Ravindran 1 , Sean Scsavnicki 1 , Walker Nelson 1 , Peter Gorecki 1 , Jacob Franz 1 ,
Shane Oberloier 2 , Theresa K. Meyer 3 , Andrew R. Barnard 1 and Joshua M. Pearce 2,3,4, *
1 Department of Mechanical Engineering–Engineering Mechanics, Michigan Technological University,
Houghton, MI 49931, USA; [email protected] (A.R.); [email protected] (S.S.); [email protected] (W.N.);
[email protected] (P.G.); [email protected] (J.F.); [email protected] (A.R.B.)
2 Department of Electrical & Computer Engineering, Michigan Technological University, Houghton,
MI 49931, USA; [email protected]
3 Department of Material Science & Engineering, Michigan Technological University, Houghton,
MI 49931, USA; [email protected]
4 Department of Electronics and Nanoengineering, School of Electrical Engineering, Aalto University,
FI-00076 Espoo, Finland
* Correspondence: [email protected]; Tel.: +1-906-487-1466




Received: 30 August 2019; Accepted: 9 October 2019; Published: 14 October 2019


Abstract: In order to accelerate deployment of distributed recycling by providing low-cost feed

stocks of granulated post-consumer waste plastic, this study analyzes an open source waste plastic
granulator system. It is designed, built, and tested for its ability to convert post-consumer waste,
3D printed products and waste into polymer feedstock for recyclebots of fused particle/granule
printers. The technical specifications of the device are quantified in terms of power consumption
(380 to 404 W for PET and PLA, respectively) and particle size distribution. The open source device
can be fabricated for less than $2000 USD in materials. The experimentally measured power use is
only a minor contribution to the overall embodied energy of distributed recycling of waste plastic.
The resultant plastic particle size distributions were found to be appropriate for use in both recyclebots
and direct material extrusion 3D printers. Simple retrofits are shown to reduce sound levels during
operation by 4dB-5dB for the vacuum. These results indicate that the open source waste plastic
granulator is an appropriate technology for community, library, maker space, fab lab, or small
business–based distributed recycling.

Keywords: 3D printing; additive manufacturing; distributed manufacturing; distributed recycling;

granulator; shredder; open hardware; fab lab; open-source; polymers; recycling; waste plastic;
extruder; upcycle; circular economy

1. Introduction
The open-source release of the self-replicating rapid prototyper (RepRap) 3D printer [1–3] greatly
expanded access to additive manufacturing (AM) because of several orders of magnitude reduction
in costs [4]. As open-source RepRap 3D printers spawned hundreds of clones, fused filament
fabrication (FFF) enabled a shift in the trend from centralized to consumer (or prosumer) distributed
manufacturing [4–8]. Consumers now use RepRaps or pre-built desktop 3D printers to manufacture
all manner of products from toys to household items less expensively than purchasing them from
conventional brick and mortar or online retailers [9–11]. The peer-reviewed business literature now
recognizes this potential shift in manufacturing [12–14], which is brought on not only by the open
source sharing of 3D printer designs, but now more importantly because of millions of freely shared
digital designs of other products that are 3D printable [9]. Any level of consumer from scientific
research funders to arthritis patients [15] can earn a high return on investment (ROI) [16] for distributed

Technologies 2019, 7, 74; doi:10.3390/technologies7040074 www.mdpi.com/journal/technologies

Technologies 2019, 7, 74 2 of 21

manufacturing with commercial polymer 3D printing filament based on downloaded substitution

values [17]. However, commercial 3D printing filament is still sold for roughly an order of magnitude
more than the cost of the raw materials of virgin plastic pellets (e.g., $15–100 USD/kg vs $1–10 USD/kg).
This has reduced adoption of AM at the prosumer level [18]. There are two methods to overcome this
artificial cost barrier for wider spread distributed manufacturing: (1) use distributed recycling to make
filament and (2) skip the entire process of fusing filament into a 3D printed object by printing directly
from polymer granules, shards or particles.
Three-dimensional printing filament can be manufactured economically using distributed means
with an open source waste plastic extruder (often called a recyclebot) [19]). Recycling is well-known
to be environmentally beneficial, and performing distributed recycling of plastic waste into filament
decreases the embodied energy of filament by 90% compared to traditional centralized filament
manufacturing using fossil fuels as inputs [20–22]. Using distributed recycling fits into the circular
economy paradigm [23–26] as it eliminates most embodied energy and pollution from transportation
between processing steps. Many open-source commercial and non-commercial recyclebots have been
developed [27], including a 3D printable version [28]. Many research groups and companies have
demonstrated that pre-consumer and post-consumer waste polymers can be recycled into 3D printing
filaments, including

• polylactic acid (PLA) [28–32];

• acrylonitrile butadiene styrene (ABS) [24,33–36];
• high-density polyethylene (HDPE) [19,37,38];
• polypropylene (PP) [38];
• polystyrene (PS) [38];
• polyethylene terephthalate (PET) [39];
• linear low-density polyethylene (LLDPE) and low-density polyethylene (LDPE) [40];
• elastomers [8].

In addition, filaments can be made from polymer composites using carbon-reinforced plastic [41]
and various types of waste wood [42,43]. Unfortunately, each melt-solidification degrades the
mechanical properties of the resultant 3D print [44,45], so recycling is limited to about five
cycles [29,30,46] or using chemical recycling [47] without use some means of reinforcement or blending
with virgin materials. The potential for such distributed recycling could be either completely distributed
(where the consumer recycles their own plastic in their home or business) or part of a local closed-loop
supply chain [48].
The second method, however, eliminates the need for filament entirely, as 3D printers have been
developed that can print directly from particles, pellets, flakes, regrind, or shreds of recycled plastic.
These fused particle fabrication (FPF) or fused granular fabrication (FGF) 3D printers are becoming
established in the academic [49–54], maker [55–57], and commercial venues (e.g., GigabotX, PartDaddy,
Cheetah Pro, David, Erecto-Struder, etc.). FPF/FGF printing is possible with recycled materials [58–60],
as is using FGF printing of molds for distributed injection molding of larger replicate products [60].
Both the widespread deployment of distributed recycling with recyclebots and FPF/FGF are being
restricted because of the lack of accessibility of low-cost pelletizers and choppers to turn post-consumer
plastic products into polymer feedstock. In general, these are large industrial machines not conducive
for makerspaces, fab labs, research, or consumer use because of their high throughputs, noise, and
capital costs. This study attempts to a provide a new low-cost but medium-scale technology for
transforming plastic recyclables into usable 3D printing feedstock in the form of granules (or particles).
In order to provide a low-cost tool for making polymer feedstock from post-consumer waste this
study follows the open-source hardware design paradigm [61,62], which has proven so successful for
3D printing in general. A novel open source waste plastic granulator system is designed, built, and
tested for its ability to convert post-consumer waste, 3D printed products, and 3D printer waste into
polymer feedstock for recyclebots of FGF/FPF printers. Then, the technical specifications of the device
Technologies 2019, 7, 74 3 of 21

are quantified in terms of power consumption and particle size of the output. In order for the device
to operate in a fab lab (or similar environment), a noise reduction system is designed, added, and
analyzed. The results are presented and discussed.

2. Design Concept
The design of the open source waste plastic granulator system is divided into four separate
sub-systems, each responsible for parts of the machine that serve a specific function.

1. Power Transmission: This system encompasses all machine parts needed to convert the electrical
energy being input to the system into mechanical energy, as well as transmit that mechanical
energy to the plastic cutting/granulation system.
2. Plastic Cutting/Granulation: This system is the one that directly interacts with the plastic in order
to cut it into small chunks. It is responsible for cutting plastic as well as ejecting granules after
they have reached a uniform size.
3. Material Guidance/Structural: This system involves any parts that keep the plastic feedstock
inside of the proper cutting area during operation or guide the feedstock during its journey.
It includes the hopper chute, the hopper lip, the granulation chamber lip, any mechanism used to
hold the hopper to the granulation chamber, and the upper surfaces of the granulation chamber.
4. Electrical: This system encompasses all of the components required to convert electrical energy
from electrical grid power into rotational energy, as well as any other electrical peripherals
present on the machine. This includes the electrical box, safety switches, circuit board, motor, and
a microcontroller.

Together, these systems operate with the end goal of transforming plastic recyclables into usable
3D printing feedstock in the form of granules (or particles). The main concepts and parts in each
sub-system will be described, but the full open hardware details including the bill of materials (BOM),
drawings for custom parts, CAD files, build instructions, and design reports of previous versions are
housed at the Open Science Framework [63].

2.1. Power Transmission System

The power transmission system transfers rotational mechanical energy from the motor spindle to
the cutting rotor shaft. As a first step towards designing this subsystem of the machine the design
team made the decision that a one-phase AC motor (IronHorse, Automation Direct, Cumming, GA,
USA; 1–1/2hp 115/230 VAC motor, with 15.9mm shaft diameter wired for 230 V) would be used to
supply mechanical power to the machine. This method of mechanical power delivery is the most
reliable and easiest way for an individual to drive a machine from their home circuitry. Pulleys and
belts are used to convey power to the cutting rotor; belts are not only inexpensive when compared
to a gearbox but are also more user friendly since they are easy to install, maintain, and adjust once
assembled. An isolated view of the 3D model for the power transmission subsystem and all of its
components can be seen in Figure 1.
As seen in the Figure 1, the parts of the power transmission system are as follows: AC Motor,
pulleys, belts, flange-mount bearings, rotor shaft, quick-disconnect (QD) bushings, and weld-on hubs
(plus mounting hardware). The motor selected to drive the granulator is a 1.5 HP motor with a spindle
speed of ~1800 RPM. On a previous version of the open source waste plastic granulator, the optimal
rotor speed for cutting was found to be around 750 RPM [62]; this speed was also used for this design
as well, leading to a set ratio of pulley diameters of about 1:2.4. A 100.33 mm diameter pulley was
chosen to connect to the motor spindle using a quick-disconnect style bushing. A 222.25 mm diameter
pulley was used to attach to the cutting rotor shaft, also with a quick-disconnect bushing. Both pulleys
have two channels for v-belts to ensure there is no slippage during operation. In order to keep the
cutting rotor shaft spinning about its major axis, two large flange-mount bearings were used. In order
to connect the shaft to the cutting rotor, QD bushings were used in conjunction with weld-on hubs to
 The power transmission system transfers rotational mechanical energy from the motor spindle to
the cutting rotor shaft. As a first step towards designing this subsystem of the machine the design team
Technologies
made 2019, 7, x FOR
the decision thatPEER REVIEW AC motor (IronHorse, Automation Direct, Cumming, GA, USA;
a one-phase 4 of 1–
21
1/2hp 115/230 VAC motor, with 15.9mm shaft diameter wired for 230 V) would be used to supply
(plus mounting
mechanical hardware). The motor selected to drive the granulator is a 1.5 HP motor with a spindle
Technologies 2019, 7, 74power to the machine. This method of mechanical power delivery is the most reliable and 4 of 21
speed of ~1800 RPM.
easiest way for an individualOn a previous
to driveversion of the
a machine open
from source
their homewaste plastic
circuitry. granulator,
Pulleys theare
and belts optimal
used
rotor
to speedpower
convey for cutting
to thewas found
cutting to be
rotor; around
belts 750only
are not RPMinexpensive
[62]; this speed
whenwas also used
compared tofor this design
a gearbox but
as well,
are also leading
more to afriendly
user set ratiosince
of pulley
they diameters
are easy to of aboutmaintain,
install, 1:2.4. A 100.33
and mm diameter
adjust once pulley was
assembled. An would
clamp to the shaft. These components were then bolted to the cutting rotor so that the blades
chosen toview
isolated connect
of theto3D
themodel
motorforspindle using transmission
the power a quick-disconnect style and
subsystem bushing.
all of A
its222.25 mm diameter
components can be
spin with the was
pulley shaft (see
used Figure 2).
seen in Figure 1. to attach to the cutting rotor shaft, also with a quick-disconnect bushing. Both pulleys
have two channels for v-belts to ensure there is no slippage during operation. In order to keep the
cutting rotor shaft spinning about its major axis, two large flange-mount bearings were used. In order
to connect the shaft to the cutting rotor, QD bushings were used in conjunction with weld-on hubs to
clamp to the shaft. These components were then bolted to the cutting rotor so that the blades would
spin with the shaft (see Figure 2).

2.2. Plastic Cutting System

The plastic cutting subsystem is, out of all of the subsystems, the most directly related to the
overall function of the machine as it is responsible for transforming plastic waste/recyclables into
granules of a specific size. In order to do this, the design team picked out many different forms that
would satisfy the subsystem’s purpose and compared them using a decision matrix (details of which
are found in the OSF database [63]). From the decision matrix, the best option was found to be the fly
knife design, consisting of two large rotating blades (fly knives) that pass close to a fixed blade during
Figure 1. Power transmission systemdesign
design of
ofthe open source
1. Power
Figure(Figure
operation transmission
2). Shear force onsystem
the plastic betweenthethe
open
blades iswaste
source plastic
thewaste
main granulator.
plastic
cuttinggranulator.
method.

As seen in the Figure 1, the parts of the power transmission system are as follows: AC Motor,
pulleys, belts, flange-mount bearings, rotor shaft, quick-disconnect (QD) bushings, and weld-on hubs

Figure 2. Plastic cutting system design of the open source waste plastic granulator. There is about
Figure 2. Plastic cutting system design of the open source waste plastic granulator. There is about 2mm
2mm gap between the knives and the screen.
gap between the knives and the screen.
The plastic cutting system consists of four separate components (plus mounting hardware). Two
2.2. Plastic Cutting System
blade arms will connect to the cutting rotor shaft (shown in Figure 2) and will spin with the shaft.
TheConnected to either end
plastic cutting of each blade
subsystem arm of
is, out in the
all configuration shown below
of the subsystems, thearemosttwodirectly
fly knives,related
which to the
will contact the plastic within the cutting chamber and shear through it. To help with the cutting of the
overall function of the machine as it is responsible for transforming plastic waste/recyclables into
plastic granules, there are two more pieces in this system that both interact with the rotating fly knives,
granules of a specific size. In order to do this, the design team picked out many different forms that
the granulation screen and the bed blade. As the fly knives rotate in the granulation chamber, they will
would satisfy
pass verythe subsystem’s
close purpose
to the fixed bed and
blade on thecompared
right side ofthem
Figureusing
2. a decision matrix (details of which
are found inThistheisOSFwheredatabase
the large [63]).
pieces From the
entering thedecision matrix,will
cutting chamber thebebest option
sheared was
for the firstfound
time. Intothe
be the fly
design,consisting
knife design, all stress-bearing
of two components relatedblades
large rotating to this large cutting force
(fly knives) thatwere
passdesigned
close totoa be ableblade
fixed to cut during
operation22.2(Figure
mm cubes 2).ofShear
nylonforce
mill stock.
on theOnce large pieces
plastic between havethe
been cut foristhe
blades first
the time cutting
main by the bed blade,
method.
they will accumulate on the surface of the granulation screen. The clearance between the tip of the fly
The plastic cutting system consists of four separate components (plus mounting hardware).
knives during rotation and the inside of the screen in 3 mm, which means that any larger granules will
Two blade arms will connect to the cutting rotor shaft (shown in Figure 2) and will spin with the shaft.
get pinched between the screen and the blade and be sheared to a smaller size. Once the granules are
Connected to either
smaller than 6 mmendinofalleach blade arm
dimensions, they in
arethe configuration
pulled shown
through the holes below
located are
in the two fly knives,
granulation screen which
will contact the aplastic
and into within
collection chamberthe by
cutting chamber
a vacuum. andvacuum
Thus, the shear through
is used forit.
theTo help with
collection of thethegranules
cutting of the
of cut plastic.
plastic granules, In order
there to make
are two morethepieces
blade arms rotate,
in this as described
system in Section
that both 2.1,with
interact weld-onthehubs attached
rotating fly knives,
to the shaft were bolted onto the blade arms. For the cutting system fly knife blades
the granulation screen and the bed blade. As the fly knives rotate in the granulation chamber, they will were manufactured
from O1 tool steel and a Bridgeport was used to manually face fill the stock down to dimension. Once
pass very close to the fixed bed blade on the right side of Figure 2.
This is where the large pieces entering the cutting chamber will be sheared for the first time.
In the design, all stress-bearing components related to this large cutting force were designed to be
able to cut 22.2 mm cubes of nylon mill stock. Once large pieces have been cut for the first time by
the bed blade, they will accumulate on the surface of the granulation screen. The clearance between
the tip of the fly knives during rotation and the inside of the screen in 3 mm, which means that any
larger granules will get pinched between the screen and the blade and be sheared to a smaller size.
Once the granules are smaller than 6 mm in all dimensions, they are pulled through the holes located
in the granulation screen and into a collection chamber by a vacuum. Thus, the vacuum is used for
Technologies 2019, 7, 74 5 of 21

the collection of the granules of cut plastic. In order to make the blade arms rotate, as described in
Section 2.1, weld-on hubs attached to the shaft were bolted onto the blade arms. For the cutting system
fly knife blades were manufactured from O1 tool steel and a Bridgeport was used to manually face
fill the stock down to dimension. Once block was dimensioned down an end mill was used to cut
slots and pockets needed to attach the bolts. Finally, an angle vise was used to face mill the bevel
for the cutting edge
Technologies 2019, all to the
7, x FOR PEERspecifications
REVIEW with the drawings [63]. After machining the 5blades of 21 were

heat-treated using an electric furnace and quenched in oil in order to harden the tool steel following
block was dimensioned down an end mill was used to cut slots and pockets needed to attach the bolts.
standardFinally,
protocols.
an angle Forvisethewas
granulation
used to facescreen,
mill the abevel
seamless
for the pipe cut
cutting to all
edge width
to thewas used as the
specifications withstarting
material,thebut due to[63].
drawings manufacturing
After machining methods
the bladesthe
werepipe had internal
heat-treated stresses.
using an Heat treating
electric furnace the pipe in
and quenched
an electric furnace
in oil in orderand to then
hardenletting
the toolit air cool
steel relieved
following the internal
standard stresses.
protocols. For theThis step is screen,
granulation not required
a if
seamless pipe cut to width was used as the starting material, but due to manufacturing
tools are not available as one could continue to cut the pipe, but stress may not be relieved, and it will methods the
pipe had internal stresses. Heat treating the pipe in an electric furnace and then letting it air cool relieved
spring open. After the stress relief heat treatment, an angle grinder is used to cut a straight line down
the internal stresses. This step is not required if tools are not available as one could continue to cut the
the length of the pipe and then cut the other side of the pipe to provide equal halves, which are then
pipe, but stress may not be relieved, and it will spring open. After the stress relief heat treatment, an
subsequently drilledis as
angle grinder used shown
to cut ainstraight
the Figures.
line down the length of the pipe and then cut the other side of the
pipe to provide equal halves, which are then subsequently drilled as shown in the Figures.
2.3. Material Guidance
2.3. Material Guidance
The material guidance system is responsible for containing the waste plastic both before and after
The materialIn
the cutting operation. guidance
additionsystem is responsible
to guiding for containing
materials, the waste
this system plastic
also bothas
serves before and after upon
the structure
the cutting operation. In addition to guiding materials, this system also serves as the structure upon
which all other subsystems are constructed. The feedstock is guided using a sloped tube as shown in
which all other subsystems are constructed. The feedstock is guided using a sloped tube as shown in
Figure 3.Figure 3.

Material
Figure 3.Figure guidance
3. Material systemsystem
guidance (cut section and completed)
(cut section for the
and completed) foropen source
the open wastewaste
source plastic granulator.
plastic
granulator.
Overall, the main component used for material guidance is a large steel square tube that not
Overall, the main component used for material guidance is a large steel square tube that not only
only provides a smooth, enclosed surface for the waste plastic to slide on while it is on its way
provides a smooth, enclosed surface for the waste plastic to slide on while it is on its way to be cut,
to be cut, but also a very strong and rigid structure that can be built upon. Attached to this large
but also a very strong and rigid structure that can be built upon. Attached to this large (8” (203 mm)
(8” (203 width)
mm) width)
square square
tube aretube are other
several several other components
components that supportthat thesupport the plastic
plastic cutting cutting and
and power
power transmission systems.
transmission systems. The
The twotwo
largelarge rounded
rounded platesplates
attached attached to thefaces
to the vertical vertical
of thefaces of the
tube are whattube are
hold the bearings from the power transmission system in place. The angle iron
what hold the bearings from the power transmission system in place. The angle iron on the bottom on the bottom part of part
the tube serves two purposes. The larger piece holds the fixed bed blade in place
of the tube serves two purposes. The larger piece holds the fixed bed blade in place during operation, during operation,
as well as clamping to the second piece of angle iron shown, which secures the granulation screen in
as well as clamping to the second piece of angle iron shown, which secures the granulation screen in
place for cutting. The materials on the top of the tube are all responsible for holding the opposite side
place forofcutting. The materials
the granulation screen inon theand
place topallows
of thethe
tube are
user to all responsible
disconnect for holding
the granulation the quickly
screen opposite side
of the granulation
from one side. This system also includes a secondary tube acting as a hopper for funnelling materialquickly
screen in place and allows the user to disconnect the granulation screen
from onedirectly
side. from
This the
system
user’salso
handincludes a secondary
into the machine as welltube actingrack
as a server as acart
hopper
that isfor
usedfunnelling
to house thematerial
directly main
fromcutting mechanism.
the user’s hand However, these components
into the machine as well are
as anot shownrack
server above for that
cart clarity.
is used to house the
main cutting mechanism. However, these components are not shown above for clarity.
2.4. Electrical

2.4. ElectricalThe electrical system in the machine serves three purposes—powering the motor, powering the
granule extraction vacuum, and monitoring the power consumption of the machine. These functions
Theare
electrical system
accomplished in the
simply machine
since both the serves
vacuumthree purposes—powering
and the motor require no more the
thanmotor,
a simplepowering
on/off the
granule control
extraction vacuum, and monitoring the power consumption of the machine. These
scheme. Both the vacuum and the motor are connected directly to 120VAC mains power and functions
use simple simply
are accomplished switchessince
to control
both them. In addition,
the vacuum and an
theemergency-stop
motor requireswitch is included
no more in the on/off
than a simple
circuitry to cut power to the whole machine if necessary. The final accessory included in the electronic
Technologies 2019, 7, 74 6 of 21

control scheme. Both the vacuum and the motor are connected directly to 120VAC mains power
and use simple switches to control them. In addition, an emergency-stop switch is included in the
circuitry to cut power to the whole machine if necessary. The final accessory included in the electronic
Technologies 2019, 7, x FOR PEER REVIEW
circuit for this machine is a multimeter that provides a digital readout with information6on of 21
the power
consumption of the machine. All of the components in the electrical system were designed
circuit for this machine is a multimeter that provides a digital readout with information on the power to operate
using less than 15 Amps
consumption duringAll
of the machine. steady-state conditions
of the components so thatsystem
in the electrical the machine could
were designed be run off of a
to operate
standardusing less than
in-home wall15outlet.
Amps during steady-state
A circuit diagram conditions so that thesystem
for the electrical machineiscould be runin
included offFigure
of a 4a.
standard in-home wall outlet. A circuit diagram for the electrical system is included in Figure 4a.

(a)

(b)

Figure 4. (a) Circuit diagram for electrical control system of the open source waste plastic granulator
and (b) circuit diagrams.
Technologies 2019, 7, x FOR PEER REVIEW 7 of 21

Figure
Technologies 4. (a)
2019, Circuit diagram for electrical control system of the open source waste plastic granulator7 of 21
7, 74
and (b) circuit diagrams.

Peripheral Parts Assembly

2.5. Peripheral
Together, thethe four
four systems
systems described
described in
in Sections 2.1–2.4 work
Section 2.1–2.4 work together
together to achieve the overall
objective of the design of the open source waste waste plastic
plastic granulator.
granulator. Other than getting the material
from place
place to
toplace,
place,all
allofofthe
theactual
actualmanipulation
manipulation of of
thethe
plastic to transform
plastic it from
to transform stock
it from material
stock into
material
feedstock
into occursoccurs
feedstock due todue
the to
cutting and power
the cutting and transmission systems. systems.
power transmission An overallAnview of the
overall machine’s
view of the
core systems
machine’s coreis shown
systemsinisFigure
shown5.in Figure 5.

Overall design
Figure 5. Overall design setup
setup of
of the
the open
open source
source waste plastic granulator with primary parts labeled
with green arrows.
arrows. Red arrows indicate the path of material
material flow.
flow.

Figure 55 shows
Figure shows the the assembly
assembly of of the
the three
three mechanical
mechanical designdesign systems,
systems, including
including all all of
of the
the parts
parts
explained earlier as well some 3D printed parts and several parts not shown
explained earlier as well some 3D printed parts and several parts not shown before. The total system before. The total system
dimensions are
dimensions are width
width of of0.72
0.72m,m, depth
depth of of 0.55
0.55m m and
and height
height of of 1.47m.
1.47 m.The Thesystem
systemhas hasaamassmassof of125
125kg.kg.
As
As can
can be
be seen
seen inin the
the above
above picture
picture the
the server
server rack
rack cart
cart that
that was
was mentioned
mentioned in in the
the material
material guidance
guidance
system is housing the main systems of the granulator. It holds the machine components so that
system is housing the main systems of the granulator. It holds the machine components so that the
the
major axis
major axisofofthethelarge square
large tubetube
square is angled to allow
is angled to plastic
allow pieces
plastictopieces
slide into
to the
slide cutting
into themechanism.
cutting
To accomplish
mechanism. Tothis, several standard
accomplish size 12standard
this, several ” (12.7 mm)) sizesteel pipesmm))
½” (12.7 are attached to the
steel pipes areserver rack to
attached using
the
u-bolts. The pipe in the rear (as shown in Figure 5) is attached directly to the
server rack using u-bolts. The pipe in the rear (as shown in Figure 5) is attached directly to the bottom bottom of the steel tube
using
of the pipe
steelstraps, whilepipe
tube using the pipe in the
straps, whilefront
theispipe
attached
in thevia nylon
front strappingvia
is attached to the
nylon eye-bolts
strappingshown on
to the
the top of the steel tube in the above figure. This is done to allow the builder
eye-bolts shown on the top of the steel tube in the above figure. This is done to allow the builder of of the machine to easily
addmachine
the a vibration-dampening spring at the front attachment
to easily add a vibration-dampening spring at point to mitigate
the front attachment any point
rotational imbalance
to mitigate any
that may beimbalance
rotational present inthat the machine. The hopper
may be present consists
in the of theThe
machine. large tube sticking
hopper consistsout ofofthe thelarge
top oftubethe
server rack as well as a plate that allows it to attach to the back of the square
sticking out of the top of the server rack as well as a plate that allows it to attach to the back of the steel tube/main machine
body. This
square steelallows
tube/mainusersmachine
to safelybody.
place This
materials
allowsinto the to
users machine for cutting.
safely place Theinto
materials bend thethat materials
machine for
will haveThe
cutting. to pass
bendthrough in orderwill
that materials to get
havefrom the machine’s
to pass through inopening
order totogetthefrom
cutting
the mechanism
machine’s openingensures
that
to thea user
cuttingcannot accidentally
mechanism placethat
ensures their hands/arms
a user inside the machine
cannot accidentally whilehands/arms
place their it is cutting inside
as wellthe as
stops granules
machine while from flying out
it is cutting of the
as well machine
as stops duringfrom
granules operation.
flying outTo highlight the interaction
of the machine between
during operation.
all three main mechanical systems a cutaway view showing the assembled
To highlight the interaction between all three main mechanical systems a cutaway view showing the granulation chamber in
Figure 6.
assembled granulation chamber in Figure 6.
Technologies 2019, 7, 74 8 of 21
Technologies 2019, 7, x FOR PEER REVIEW 8 of 21

Figure
Figure 6. 6.Cutaway
Cutawayofofmechanical
mechanical systems
systems in
in the
the open
opensource
sourcewaste
wasteplastic
plasticgranulator.
granulator.

2.6.2.6.
Cutting Force
Cutting Design
Force DesignAnalysis
Analysis
The The cutting
cutting operationthat
operation thattakes
takesplace
place during
during the operation
operationof ofthethegranulator
granulatoris isunpredictable,
unpredictable,
so so a simulation
a simulation waswasrunrunofofthe
thecutting
cuttingforces
forces that
that occur
occur during
duringthe theoperation
operationofofthe thegranulator
granulator [63].
[63].
These forces are important because they allow for the calculation of the
These forces are important because they allow for the calculation of the stresses that occur inside thestresses that occur inside the
keykey stress-bearing
stress-bearing elementsofofthe
elements thedesign.
design.The The method
method and and findings
findingsare areininthe
theOSFOSFdatabase
database[63].
[63].
The stress levels inside the blade arm as well as the fly knife bolts are well belowthe
The stress levels inside the blade arm as well as the fly knife bolts are well below acceptable
the acceptable
level
level forfor steel
steel materials.InInorder
materials. ordertotoachieve
achieve this,
this, it
it was
was determined
determinedthat thatthe
theblade
bladearmsarmsmust
must bebemade
made
out of 19 mm × 63.5 mm steel flat stock, and that the bolts must
out of 19 mm × 63.5 mm steel flat stock, and that the bolts must be 16 UNC (9.525 mm) grade be 16 UNC (9.525 mm) grade 8 hex
8 hex
cap screws. Previous simulations found that a 12.7 mm thick piece of angle iron with side lengths of
cap screws. Previous simulations found that a 12.7 mm thick piece of angle iron with side lengths of
76.2 mm would be suitably strong for this piece. In this study, 6.35 mm–20 UNC bolts were selected
76.2 mm would be suitably strong for this piece. In this study, 6.35 mm–20 UNC bolts were selected
despite being over engineered because they proved inexpensive for this application. After iterating
despite being over engineered because they proved inexpensive for this application. After iterating the
the simulation to find the optimal size for the bed blade mounting bolts, both locations were
simulation to find the optimal size for the bed blade mounting bolts, both locations were considered,
considered, and 912.7 mm −12 UNC grade 8 hex cap bolts were chosen. Standard fatigue analysis [64]
andwas912.7 mm −12and
performed, UNC
it wasgrade
found 8 that
hex the
capgrade
bolts 9werebolts chosen.
responsible Standard fatigue
for attaching theanalysis
fly knife [64]
blades was
performed,
to the blade arms are predicted to fail due to fatigue before infinite life. That being said, the analysisthe
and it was found that the grade 9 bolts responsible for attaching the fly knife blades to
blade
done arms are predicted
assumes that a 19 to mm failnylon
due to fatigue
block will before
enter theinfinite
machinelife.once
Thatevery
beingtimesaid,onetheknife
analysis done
rotates,
assumes
which, for normal operation, is very unlikely. For normal use, the stresses present will never reachfor
that a 19 mm nylon block will enter the machine once every time one knife rotates, which,
normal operation,
the values used for is very unlikely.
analysis. For normal
However, use, the stresses
users planning on usingpresent will never
this machine reachrecycling
for nylon the values
used for analysis.
should replace theseHowever, usersmonth
bolts every planning on using
in order thisfailure
to avoid machine duefor nylon recycling
to fatigue. The maximum shouldtorque
replace
these bolts
acting onevery monthrotor
the cutting in order
duringto avoid failure
operation due to fatigue.
is slightly less thanThe 1500 maximum
N-m. In order torquetoacting
attachon thethe
cutting
cutting rotor
rotor to the operation
during shaft two SK type QDless
is slightly bushings
than 1500wereN-m. chosen, since each
In order bushing
to attach the can support
cutting rotora to
thetorque
shaft twoof about
SK type800 N-m. Together, were
QD bushings these two bushings
chosen, sincecan eachsupport
bushing a maximum
can support torque of 1580ofN-m,
a torque about
800a N-m.
torqueTogether,
that should never
these twobebushings
exceededcan during the normal
support a maximumoperation of the
torque ofmachine.
1580 N-m, In conclusion,
a torque that
the design
should neversimulation
be exceeded indicated
duringthat the the technology
normal operationas designed would beIn
of the machine. able to cut a maximum
conclusion, the design
thickness of nylon stock of 19 mm, i.e. a cube measuring
simulation indicated that the technology as designed would be able to cut a maximum 19 mm on each side is the largest piece of of
thickness
plastic
nylon stock
stock thatmm,
of 19 should
i.e.,be inserted
a cube into the machine.
measuring 19 mm on each side is the largest piece of plastic stock
that should be inserted into the machine.
3. Material and Methods
3. Material and Methods
3.1. Technical Specifications: Power Consumption and Particle Size
3.1. Technical Specifications:
The power Poweroperating
consumption Consumption and ParticleasSize
the granulator measured with an open-source printed
circuit board and Arduino Nano attached to the power supply
The power consumption operating the granulator as measured to with
measure the power output
an open-source printedofcircuit
the
while
board andit Arduino
was processing different
Nano attached materials.
to the Duringtoeach
power supply of the
measure the power recording
power output sessions,
of the while it
Technologies 2019, 7, 74 9 of 21
Technologies 2019, 7, x FOR PEER REVIEW 9 of 21

was processingwas
thermoplastic different
inserted materials. During
at a rate each of thecould
the granulator power recording
handle. Thissessions,
rate is not thermoplastic
measured, as was it
inserted at a rate the granulator could handle. This
highly depends on the geometry and density of the inserted plastic. rate is not measured, as it highly depends on the
geometry
The ACandpower
density of the inserted
measurement plastic.
system is a custom system designed for measuring and recording
general AC power consumption data. isThe
The AC power measurement system a custom
devicesystem designed for
is prototyped as measuring
a custom and recording
professionally
general AC power consumption data. The device is prototyped as a custom
manufactured printed circuit board (PCB). The PCB was then soldered by hand. The system is professionally manufactured
printed
capablecircuit boardfour
of making (PCB). The PCB
separate AC was then soldered by
measurements. Each hand.
leg’sThe system is capable
measurements of making four
are connected to a
separate AC measurements. Each leg’s measurements are connected
dedicated Analog Devices ADE7757 energy metering integrated circuit (IC). The IC meets to a dedicated Analog Devices
the
ADE7757 energy metering integrated circuit (IC). The IC meets the IEC61036
IEC61036 accuracy requirements for power measurements. The ADE7757 transmits the wattage accuracy requirements for
power measurements. The ADE7757 transmits the wattage signal through
signal through its CF pin, and is captured by the on-board Arduino Nano. An overall system its CF pin, and is captured
by the on-board
schematic is shownArduino Nano.
in Figure 4b.An overall system schematic is shown in Figure 4b.
For
For analyzing
analyzing the the power
power consumption
consumption of of the
the shredder,
shredder, both both input
input legs
legs ofof the
the 220
220 VAC
VAC power
power
input
input to the control electronics are monitored. Each leg’s corresponding voltage is measured by
to the control electronics are monitored. Each leg’s corresponding voltage is measured by direct
direct
connection,
connection, and current is measured using 100A non-invasive current transformers. The values are
and current is measured using 100A non-invasive current transformers. The values are
operated
operated on on by
by aa linear
linear calibration,
calibration, and
and then
then written
written toto aa microSD
microSD card,
card, with
with time
time stamps
stamps generated
generated
by
by the
the on-board
on-board real real time
time clock.
clock. The
The size
size characteristics
characteristics of of the
the particles
particles for
for the
the resultant
resultant granulated
granulated
material were quantified using digital imaging and the open source Fiji/ImageJ
material were quantified using digital imaging and the open source Fiji/ImageJ using techniques using techniques
discussed previously [60].
discussed previously [60]. ImageJ
ImageJworks
worksbybyanalyzing
analyzing a photograph
a photograph of of
thethe particles
particles andand raising
raising the
the contract of the photograph until all particles are clearly recognizable
contract of the photograph until all particles are clearly recognizable to the program as solid blackto the program as solid
black
pieces.pieces.
From the From the analysis,
analysis, a spreadsheet
a spreadsheet of data of data is produced
is produced with thewith
surfacethe area
surface area particle.
of each of each
particle.
This is then plotted in a histogram to provide a quantifiable understanding of the particle size
This is then plotted in a histogram to provide a quantifiable understanding of the particle size
distribution. Each analysis was repeated
distribution. Each analysis was repeated three times. three times.

3.2. Noise Reduction

3.2. Noise Reduction
Sound pressure levels (SPL) were measured using a free field array microphone positioned in
Sound pressure levels (SPL) were measured using a free field array microphone positioned in
front of the vacuum inlet of the machine at a distance of approximately 0.3m from the open source
front of the vacuum inlet of the machine at a distance of approximately 0.3m from the open source
waste plastic granulator. The measurements were logged using a National Instruments (Austin, TX,
waste plastic granulator. The measurements were logged using a National Instruments (Austin, TX,
USA) compact DAQ data acquisition system in conjunction with custom LabVIEW software. Multiple
USA) compact DAQ data acquisition system in conjunction with custom LabVIEW software. Multiple
positions were considered before finalizing on the position in Figure 7 due to repeatability and high
positions were considered before finalizing on the position in Figure 7 due to repeatability and high
signal-to-noise ratio. All trials were performed using this microphone position Sources of sound in the
signal-to-noise ratio. All trials were performed using this microphone position Sources of sound in
machine includes the shear cutting mechanism in the granulator and the shop vacuum. Although the
the machine includes the shear cutting mechanism in the granulator and the shop vacuum. Although
microphone location was not in the operator ear position, it was appropriately placed for before/after
the microphone location was not in the operator ear position, it was appropriately placed for
insertion loss measurements.
before/after insertion loss measurements.

Figure 7. Sound measurement test setup depicting the microphone

microphone in
in one
one of
of the
the test
test locations.
locations.

Tests were performed to find the sound pressure levels of the open source waste plastic
granulator system including the auxiliary devices such as the vacuum pump and the individual
contributions as well. It was determined that the vacuum pump was the loudest source with a distinct
Technologies 2019, 7, 74 10 of 21

Tests were performed to find the sound pressure levels of the open source waste plastic granulator
system including the auxiliary devices such as the vacuum pump and the individual contributions
Technologies
Technologies 2019, 7, xx FOR
FOR PEER
PEER REVIEW 10 of 21
as well. It 2019,
was 7,determined REVIEW
that the vacuum pump was the loudest source with a distinct peak10inofthe 21

250
peak Hz one third-octave band. Panel gaps in the enclosure for the granulator provides leakage paths
peak inin the
the 250
250 Hz Hz one
one third-octave
third-octave band.
band. Panel
Panel gaps
gaps in
in the
the enclosure
enclosure for
for the
the granulator
granulator provides
provides
for the
leakage sound and hence it was decided to seal these gaps appropriately. The inner lining of the walls
leakage paths
paths for
for thethe sound
sound and
and hence
hence itit was
was decided
decided to
to seal
seal these
these gaps
gaps appropriately.
appropriately. The
The inner
inner
was
liningpacked
of the with
walls open-celled
was packed foam
with to increase sound
open-celled foam absorption
to increase and transmission
sound absorption loss,transmission
and as shown in
lining of the walls was packed with open-celled foam to increase sound absorption and transmission
Figure
loss, 8.
loss, as
as shown
shown in in Figure
Figure 8.
8.

Figure 8. Granulator
Figure 8. Granulator panel
panel gaps
gaps filled
filled with
with sound
sound proofing
proofing material.
material.

Using
Using the
the initial
initial acoustic
acoustic measurements,
measurements, an an expansion
expansion chamber
chamber waswas designed
designed (Figure
(Figure 9)9) that
that
could be attached to the five-gallon bucket shop vacuum, and a 3D model was
could be attached to the five-gallon bucket shop vacuum, and a 3D model was produced to utilize produced to utilize
PVC
PVC and
and aa 3D
3D printable
printable components
components to to reduce
reduce noise
noise from
noise from the
from the operation
the operation of
operation of the
of the device.
the device. As
device. As 250Hz
250Hz waswas
the
the chosen frequency one third octave band for attenuation, the double tuned expansion chamber
chosen frequency one third octave
octave band
band for
for attenuation,
attenuation, the double tuned expansion
expansion chamber
design
design was
design waschosen
was chosenasas
chosen asit provides
it
it provides
providesgood transmission
good
good loss loss
transmission
transmission around
loss the frequency
around
around the of interest
the frequency
frequency of while having
of interest
interest while
while
good
havingattenuation
good around
attenuation the octave
around bands
the octaveas well
bands[65].
as However,
well [65]. the muffler
However, theaids in
muffler
having good attenuation around the octave bands as well [65]. However, the muffler aids in higher higher
aids frequency
in higher
attenuation
frequency and by lining
frequency attenuation
attenuation andthe
and byinner
by liningwalls
lining the of thewalls
the inner
inner muffler
walls of with
of the
the fiberglass
muffler
muffler withfoam.
with fiberglass
fiberglass foam.
foam.

Figure
Figure 9. Comparison between computer aided design (CAD) of
of chamber and
and finished expansion
Figure 9. 9. Comparison
Comparison between
between computer
computer aided
aided design
design (CAD)
(CAD) chamber
of chamber finished
and finished expansion
expansion chamber.
chamber.
chamber.

4.
4. Results
Results

4.1.
4.1. Technical
Technical Specifications
Specifications for
for Particle
Particle Size
Size and
and Energy
Energy Use
Use
Figure
Figure 10
10 shows
shows the
the resultant
resultant particles
particles and
and particle
particle size
size distribution,
distribution, where
where it
it is
is clear
clear that
that the
the
majority of particles are fines with total areas under 10 mm 2. These particle sizes are appropriate for
majority of particles are fines with total areas under 10 mm . These particle sizes are appropriate for
2

the
the majority
majority of
of recyclebots
recyclebots as
as well
well as
as direct
direct material
material extruder–based
extruder–based 3D 3D printers
printers such
such asas the
the Gigabot
Gigabot
X [58–60].
X [58–60].
Technologies 2019, 7, 74 11 of 21

4. Results

4.1. Technical Specifications for Particle Size and Energy Use

Figure 10 shows the resultant particles and particle size distribution, where it is clear that the
majority of particles are fines with total areas under 10 mm2 . These particle sizes are appropriate for
the majority of recyclebots as well as direct material extruder–based 3D printers such as the Gigabot
X [58–60].
Technologies 2019, 7, x FOR PEER REVIEW 11 of 21

Figure
Figure 10.10. Resultantparticle
Resultant particlesize
sizedistribution mm22after
distribution in mm aftershredding
shreddingininthe open
the source
open granulator.
source granulator.
Inset: picture of shredded PLA from failed 3D
Inset: picture of shredded PLA from failed 3D prints.prints.

This
This power
power drawdraw of the
of the openopen source
source waste
waste plastic
plastic granulator
granulator was was processed,
processed, andresults
and its its results
appear
appear
below in abelow
Tablein
1. aThe
Table 1. Thepower
average average powerdepending
varied varied depending on the
on the type type of and
of plastic plastic and be
would would be
expected
to expected to change
change based on thebased onfeedstock
type of the type (e.g.,
of feedstock (e.g.blocks
large solid large vs
solid blocksThe
flakes). vs time
flakes). The time
to process to of
a kg
process a kg of waste plastic ranged between
waste plastic ranged between 15 min to 30 min. 15 min to 30 min.

Table1.1. Power
Table Power consumption
consumption details.
details.
PET (Polyethylene ABS (Acrylonitrile
PLA (Polylactic Acid) PET (Polyethylene ABS (Acrylonitrile
PLA (Polylactic Acid) Terephthalate) Post- Butadiene Styrene)
Infill Terephthalate) Post-Consumer Butadiene Styrene)
Infilland
andFailed
FailedPrints
Prints Consumer Water Bottles Injection Molded
Water Bottles Injection Molded
Average
Average power 403.6(+/−50
(+/−50W)
W)* * 383.9
403.6 383.9 WW 460.0
460.0 W W
power
Average time 16 min 15 min 28 min
Average time 16 min 15 min 28 min
* Note: The PLA power depended in part on the nature of the 3D printed waste with the more solid components
* Note: The PLA power depended in part on the nature of the 3D printed waste with the more solid
taking longer.
components taking longer.

4.2. Noise Reduction Results

The noise reduction modifications to the granulator were verified with sound level
measurements and are as shown in Figures 11–13. Compared to the earlier design, a 4dB (1.5 dBA)
overall reduction in sound levels was achieved with attenuation at the 250Hz one third octave band
particularly. As the focus of the noise reduction was concentrated toward the vacuum, a 5 dB (3.2
dBA) reduction was achieved here.
Technologies 2019, 7, 74 12 of 21

4.2. Noise Reduction Results

The noise reduction modifications to the granulator were verified with sound level measurements
and are as shown in Figures 11–13. Compared to the earlier design, a 4dB (1.5 dBA) overall reduction
in sound levels was achieved with attenuation at the 250Hz one third octave band particularly. As the
focus of the noise reduction was concentrated toward the vacuum, a 5 dB (3.2 dBA) reduction
Technologies 2019, 7, x FOR PEER REVIEW
was
12 of 21
achieved here.
Technologies 2019, 7, x FOR PEER REVIEW 12 of 21
100
Current
Current LZeq
100
Previous
Current
90 Previous LZeq
Current LZeq
Previous
90 Previous LZeq

80

80

70

70

60

60
SPL (dB)

50
SPL (dB)

50

40

40

30

30

20

20

10

10

0
20 25 31.5 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000
Frequencies (Hz)
0
20 25 31.5 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000
Frequencies (Hz)
Figure 11. Results of the sound reduction redesign showing a bar plot of 1/3 octave noise
Figure 11.Results
11. Results
measurements. of the
of sound reduction
the sound redesign
reduction showingshowing
redesign a bar plotaofbar
1/3 octave noise
plot of 1/3measurements.
octave noise
measurements.
SPL (dBA)
SPL (dBA)

12.Results
Figure 12. Results of sound
of the the sound reduction
reduction redesign
redesign showingshowing
a bar plotaofbar plot of
1/3 octave 1/3measurements
noise octave noise
Figure
with dBA12.(A-weighted
measurements Results of decibels)
with dBA the sound reduction
decibels)redesign
weighting.
(A-weighted showing a bar plot of 1/3 octave noise
weighting.
measurements with dBA (A-weighted decibels) weighting.
The overall levels are approximately at 94 dB (90 dBA) and according to OSHA, four hours of
exposure time is the maximum to prevent hearing damage while operating this device. It is therefore
recommended to wear hearing protection equipment while operating the device.
(dBA)
(dBA)
SPLSPL
Technologies
Figure 12.7, 74
2019, 13 of 21
Results of the sound reduction redesign showing a bar plot of 1/3 octave noise
measurements with dBA (A-weighted decibels) weighting.

SPL (dBA)

Figure 13. Results

Figure 13. Results of
of the
the sound
sound reduction
reduction redesign
redesign on
on the
the vacuum
vacuum showing
showing aa bar
bar plot
plot of
of 1/3
1/3 octave
octave
noise measurements with dBA weighting.
noise measurements with dBA weighting.

5. Discussion

5.1. Technical Specifications for Particle Size, Throughput, and Energy Use
The particle sizes demonstrated in Figure 10 are small enough to use in a wide array of recyclebots
(both commercial and homemade) as well as for direct printing via FPF/FGF as demonstrated in
references [58–60].
The volumes that the device can process are appropriate for small businesses [13], community
centers, libraries, maker spaces, and fab labs [59,66] that could potentially become community
distributed recycling centers. There are challenges with this approach throughout the world. Although
libraries in Finland, for example, routinely offer their patrons free 3D printing services, many countries
do not. In addition, the actual recycling process can be challenging due to lack of appropriate
information in specific countries. For example, China has a sophisticated recycling symbol system [67]
that covers a wide range of waste plastics, and the US groups most of its polymers together in only 1 of
7 categories (7 = “other”) [68]. In order to have low-cost distributed recycling waste plastics need to
be appropriately labeled. The open source 3D printer community has already devised a voluntary
recycling code based on China’s comprehensive system [68]. To have a more widespread impact and
reach a cradle-to-cradle material cycle [69], regulations that demand that manufacturers identify the
materials in their products appear necessary [70].
The power draw for the open source waste plastic granulator is relatively mild, drawing as
much power as 3-4 conventional incandescent light bulbs. Coupling this low power use to the rapid
throughput of the technology results in a relatively low embodied energy of electricity for grinding
plastic with this machine. This is close to values that have been reported for commercial devices used
in previous studies of distributed recycling using additive manufacturing [20,21].

5.2. Noise Reduction

Sealing the exhaust port of the suction vacuum with the muffler did reduce the noise levels
experienced, which make the system more amenable to non-production facility-based applications
like mixed-use fab labs. As stated in the results, a 4 dB overall reduction from the granulator and the
suction vacuum combined was obtained, and hence the muffler served the intended purpose. However,
efforts to control granulator noise were not as successful, and this was possibly due to existing panel
gaps in the enclosure. They were not sealed off due to need for ease of access. Future work is needed
to explore other methods of sound reduction.
Technologies 2019, 7, 74 14 of 21

5.3. Future Work

This technology is an open source technology built on prior designs [71] and will continue to
evolve in the traditional open source fashion. There are thus several areas of future work to improve
on the design of the open source waste plastic granulator. First, the cost of the materials for the device
is $1943.11 USD, which limits its accessibility throughout many applications. The breakdown in the
cost of the2019,
Technologies materials
7, x FORisPEER
summarized
REVIEW in Figure 14 and detailed in Table 2. 14 of 21

Cost breakdown
Figure 14. Cost
Figure breakdown of
of the
the bill
bill of
of materials
materials for the open source granulator.

Table 2. Costs of all the components and numbers and sub-systems in the bill of materials for the open
Table 2. Costs of all the components and numbers and sub-systems in the bill of materials for the
source granulator.
open source granulator.
Component Group
Category Piece Function Price Quantity Component Group
Category Piece Function Price Quantity Total Cost Total Cost
Total Cost Total Cost
8" Square Steel Tube
8" Square Steel Tube 18" Main Body 85.18 1 85.18
18" Length Main Body 85.18 1 85.18
Length
1/2" 3" × 3" Angle Iron
1/2" 3" × 3" Angle Iron 8" Bed Blade Mount 10.56 1 10.56
8" Length Bed Blade Mount 10.56 1 10.56
Length
3/4" ×Flat
3/4" × 2-1/2" 2-1/2" Flat12"
Stock Stock
Flyknife Arms 10.43 1 10.43
12" Length Flyknife Arms 10.43 1 10.43
Length
8" OD
8" OD 7.5" ID7.5"
SteelIDTube
Steel8"
Tube 8"
Granulation
Granulation Screen Screen 55.255.2 11 55.2
55.2
Length
Length
1/4"Plate
1/4" Steel × 10"8" × 10" BearingBearing
Steel8"Plate Plates Plates 17.66
17.66 22 35.32
35.32
1/4"
Steel/Structural × 3/4"
1/4" Steel
× Flat
3/4" Bar
Steel 8"
Flat Bar Granulation Screen Screen
Granulation $ 594.88
3.893.89 11 3.89
3.89
Length8" Length Back Spacer
Back Spacer
3/4" × 3/8"
3/4"××1/8"
3/8"Steel
× 1/8" Steel Hinge Mount
Hinge Plate
Mount
4.684.68 22 9.36
9.36
Channel Channel 6" Length
6" Length Plate Connectors
Connectors
2" × 1-1/2"
2" ××1-1/2"
1/4" Steel Granulation
× 1/4" Steel Angle Screen
Granulation
6.326.32 11 6.32
6.32
Angle 8"8" Length
Length Clamp Screen Clamp
Steel/Struc
1/2" × 1"1/2"
6061 Aluminum
× 1" 6061 AluminumGranulation Screen Screen
Flat Granulation $ 594.88
tural 3.993.99 11 3.99
3.99
Flat BarBar
3" 3"
Length
Length Front Shims
Front Shims
Norco R4-15U ServerServer
Norco R4-15U Rack RackCart/Body Structure
Cart/Body Structure 182182 11 182
182
Server Rack Mounting
1/2" Steel Pipe 24" Length Server Rack 5.58 2 11.16
1/2" Steel Pipe 24" Length InterfaceMounting Interface 5.58 2 11.16
Polypropylene hanging Support front of
7.25 2 14.5
strap granulator
8" × 12" × 1/4" Steel Flat Motor Mount Plate 12.95 1 12.95
Toggle Pull
1 3/4" × 1/4" × 8" Steel Flat 2.24 1 2.24
Connection Plate
8" × 8" × 1/2" Plywood
Hopper Closure 20 1 20
Sheet
6" PVC Elbow Hopper Part 20.42 1 20.42
Technologies 2019, 7, 74 15 of 21

Table 2. Cont.

Component Group
Category Piece Function Price Quantity
Total Cost Total Cost
Support front
Polypropylene hanging strap 7.25 2 14.5
of granulator
8" × 12" × 1/4" Steel Flat Motor Mount Plate 12.95 1 12.95
Toggle Pull
1 3/4" × 1/4" × 8" Steel Flat 2.24 1 2.24
Connection Plate
Steel/Structural $ 594.88
8" × 8" × 1/2" Plywood Sheet Hopper Closure 20 1 20
6" PVC Elbow Hopper Part 20.42 1 20.42
6" PVC Flange Hopper Part 19.36 1 19.36
6" PVC Section Hopper Part 17 1 17
Various 3D Printed Parts Various Things 75 1 75
Indoor Steel Enclosure with Electronics
12.53 1 12.53
Knockouts Enclosure
Screw-Down Cord Grip for
Conduit Holder 1.88 3 5.64
Building Cable
DC 6.5-100V 0-100A Energy
20 1 20
LCD Display Usage Display
Cable
Heat Shrink Tubing 20 1 20
Management Stuff
Electrical $ 218.96
12-3 AC Power Cable Power Cable 64.77 1 64.77
Machine
SPST Switch rated for >15A 4.18 2 8.36
On/Off Switch
Limit Switch Z-15E Safety Switch 17.08 1 17.08
Emergency Power
Emergency Stop Switch 44.93 1 44.93
Interruption
5 gal 1.75-Peak HP Wet Granule
21.97 1 21.97
Dry Vac Retrieval Vacuum
15 amp circuit breaker replace failing fuse 3.68 1 3.68
1.5HP motor iron horse Motor 165 1 165
Adjustable Motor
Sliding mount 21.62 1
Mounting
8.95" OD Double
Shaft Pulley 52.36 1 52.36
V-Belt Pulley
3.75" OD Double
Motor Pulley 27.13 1 27.13
V-Belt Pulley
To transmit power
V-belts 13.38 2 26.76
from motor to shaft
Power Carbon Steel 40mm Diameter $ 895.40
Transmission Rotor Shaft 77.72 1 77.72
Keyed Shaft
Rotor Shaft Bushing
SK Style QD Bushing
(Blade 35 3 105
40mm Bore
Arms & Pulley)
SH Style QD Bushing Motor
16.73 1 16.73
5/8" Bore Pulley Bushing
SK Style Weld-on Blade
86.99 2 173.98
Bushing-Bore Hub Arm Connector
40mm Cast Flange Bearings Rotor Shaft Bearings 50.36 2 100.72
Blades Blades 50 3 150
Technologies 2019, 7, 74 16 of 21

Table 2. Cont.

Component Group
Category Piece Function Price Quantity
Total Cost Total Cost
Mount Bearing to
M16 Locknuts (10 Pack) 13.15 1 13.15
Plates
M16 × 45 Hex Cap Screws Mount Bearing to
11.35 1 11.35
(5 Pack) Plates
Mount Channel
1/4" - 20 × 3/4" Hex Cap
Stock to Main 0.17 4 0.68
Screw Grade 8
Body Tube
Mounting Shims to
1/4" - 20 × 4/3" Flat Head Torx
Bed Blade 1.99 4 7.96
Drive Machine Screws
Angle Iron
5/16" - 18 × 2" Hex Cap Screw Cutting Rotor
0.45 2
Grade 8 Hub Bolts
5/16" - 18 × 2 1/2" Full
Cutting Rotor
ThreadHex Cap Screw 0.53 2
Hub Bolts
Grade 8
5/16" - 18 × 1 3/8" Hex Cap Cutting Rotor
0.95 2
Screw Grade 9 Hub Bolts
3/8" - 16 × 7/8" Hex Cap Mount Pull Action
0.31 6 1.86
Screw Grade 8 Toggle Clamp
3/8" - 16 × 5/8" Hex Cap Various
0.3 12 3.6
Screw Grade 8 Mounting Stuff
3/8" - 16 × 1" Hex Cap Screw Motor Plate
0.32 2 0.64
Grade 8 Mounting
3/8" - 16 × 1 5/8" Hex Cap Granulation Screen
1.28 4 5.12
Screw Grade 8 Clamp Downs
Hardware Various Mounting $ 227.58
3/8*" - 16 Locknut Grade 8 0.22 6 1.32
Stuff
Standoffs for Pull
3/8" Nylon Washers
Action 2.25 1 2.25
(Pack of 25)
Toggle Clamp
1/2" – 13 × 1-1/2" Hex Cap
Flyknife Blade
Screws Grade 9 Extreme 8.77 1 8.77
Mounting
Strength (Pack of 5)
Mounting Bed Blade
1/2" - 20 × 7/8" Hex Cap
Angle Iron to Square 0.95 4 3.8
Screws Grade 8
Tube Housing
1/2" - 20 × 1 3/4" Hex Cap
Bed Blade Mounting 1.19 3 3.57
Screws Grade 8
1/2" - 20 Locknut Grade 8 Bed Blade Mounting 1.14 3 3.42
Granulation
1/4" - 20 × 3/4" Socket Screw 0.17 4 0.68
Screen Hardware
Granulation
1/4" - 20 × 7/8" Socket Screw 0.18 4 0.72
Screen Hardware
Hardware
10-24 × 3/8" Hex Cap Screw
Mounting to Main 11.5 1 11.5
Grade 8 (25 Pack)
Body Tube
1/2" Pipe Strap Clamp Frame Hardware 1.43 2 2.86
Adjustable
Motor Mount 21.62 1 21.62
Motor-Mounting Base
Granulation
Pull Action Toggle Clamp 26.87 1 26.87
Screen Connection
Front Square Tube
1/2" × 20 Threaded Eye Bolts Webbing 3.01 2 6.02
Connections
Technologies 2019, 7, 74 17 of 21

Table 2. Cont.

Component Group
Category Piece Function Price Quantity
Total Cost Total Cost
Server Rack
1" Black Oxide U-Bolts Connection 0.78 4 3.12
Hardware
Surface Mount Cabinet Hinge Hopper
9.12 1 9.12
(1 pair) Cover Hinges
Standoffs for
Channel Stock
1/4" Spacers, 1/4" Height 0.5 6 3
Mounting
Hardware
Closing Mechanism
Draw Latches 6.77 2 13.54
for Hopper Plate
Wood Screws for
Attaching Draw
Various Wood Screws 5 1 5
Hardware Latches and Hinges $ 227.58
to Plywood Hopper
Hardware for
Attaching PVC
Flange to Plywood
Various Nuts/Bolts Hopper Cover & 10 1 10
For Attaching Draw
Latch to Square
Tube Housing
Drill Guide for
Bronze Flange Bearing 3.43 1 3.43
Granulation Screen
Threadlocker—Blue Securing Bolts 20.38 1 20.38
Key Stock QD Hub Securing 5.24 1 5.24
Cutting Holes in
40mm Carbide Hole Cutter
Blade Arms & 16.99 1 16.99
(2 pack)
Side Plates
Fiberglass Utility Roll,
Sound Reduction Noise attenuation 6.29 1 6.29 $ 6.29
16 × 3/4 × 48-In, Frost King
$ 1943.11

To further drive down costs, additional components should be redesigned to use digital
manufacturing technologies, the mass of parts should be minimized to maintain the necessary
mechanical integrity (which is most easily done in the reduction of structural steel that makes up nearly
a third of the cost), and the volume footprint of the device should be reduced. These costs were for
retail-purchased materials and would be expected to drop significantly if an open hardware company
built the devices at even modest scale. In addition, there are several areas of technical work that may
improve the results of the technology for different polymers including detailed studies on the size,
morphology, and distribution for different types of polymers, as well as their form (e.g., 3D printed
waste, food containers, or industry bulk waste). In addition, the impacts of the heat generated in the
machine can be quantified to determine if it has any effect on the material quality.

6. Conclusions
This study successfully demonstrates the designs, build, and testing of an open source waste
plastic granulator for its ability to convert post-consumer waste, 3D printed products, and 3D printer
waste into polymer feedstock for recyclebots of fused particle/granule printers. The device can be
built from open source plans using materials that cost less than $2000 USD. The device has a power
consumption (380 to 404W for PET and PLA, the most common post-consumer plastic waste and
most popular 3D printer plastic, respectively). With this device, granules can be produced with a
particle size distribution consistent with distributed recycling and manufacturing using open source
recyclebots and 3D printers. Simple retrofits for the open source waste plastic granulator are shown to
Technologies 2019, 7, 74 18 of 21

reduce sound levels during operation by 4dB and 5dB for the vacuum. It can be concluded that the
open source waste plastic granulator is an appropriate technology for community, library, maker space,
fab lab, or small business–based distributed recycling.

Author Contributions: Conceptualization, J.M.P.; Data curation, A.R., S.S., W.N., P.G., J.F., S.O. and T.K.M.; Formal
analysis, A.R., W.N., P.G., J.F., S.O., T.K.M., A.R.B. and J.M.P.; Funding acquisition, J.M.P.; Investigation, A.R., S.S.,
W.N., P.G., J.F., S.O. and T.K.M.; Methodology, A.R., W.N., P.G., S.O. and T.K.M.; Resources, A.R.B. and J.M.P.;
Supervision, J.M.P.; Validation, A.R., S.S., W.N., P.G., S.O. and T.K.M.; Visualization, A.R., W.N., J.F., and P.G.;
Writing—original draft, A.R. and J.M.P.; Writing—review & editing, A.R., S.S., W.N., P.G., S.O., J.F., T.K.M., A.R.B.
and J.M.P.
Funding: This research was funded by the Witte Endowment.
Acknowledgments: The authors would like to acknowledge technical support from Paul Fraley and Dan Seguin.
Conflicts of Interest: The authors declare no conflict of interest. The funders had no role in the design of the
study; in the collection, analyses, or interpretation of data; in the writing of the manuscript, or in the decision to
publish the results.

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