Never has there been so much discussion of environmental damage and awareness of our impact on the planet. Whatever the sector, environmental protection is at the heart of many concerns, and the 3D printing market is no exception. With the rise of additive manufacturing also comes the need to adopt sustainable practices that reduce waste and promote a circular economy. One of the ways to achieve this is by transforming and reusing waste materials. 3devo, a Dutch company specializing in the development and recycling of 3D printing materials, has developed a solution for recycling MJF/SLS powder waste into high-quality 3D printing filament.
MJF and SLS are both powder-based 3D printing technologies but differ in key aspects. For example, MJF produces parts with more uniform mechanical properties and better surface finishes, while SLS offers a broader range of materials and finer resolution for intricate details. Both MJF and SLS powders can be processed efficiently by 3devo’s recycling system. In so doing, the company is promoting and encouraging a circular economy. Here, we provide a practical step-by-step guide to converting MJF and SLS powder waste into reusable FDM filament using 3devo’s innovative technology.
1. Assemble Required Equipment
Before diving into the recycling process, it is essential to gather all necessary tools and machinery for converting MJF powder into FDM filament. This includes the primary equipment, such as the 3devo Filament Maker, and any auxiliary tools that might facilitate the process, such as clean containers for sorting the powder and precision measuring tools to ensure accurate weight measurements.
Assembling the required equipment ensures that the process runs smoothly and reduces downtime. The 3devo Filament Maker is compact yet powerful and is designed to be a user-friendly, all-in-one solution for filament production. Its streamlined design replaces the complex, multi-component systems traditionally used for filament extrusion, saving both space and reducing operational complexity.
2. Prepare MJF Waste Powder
Preparation of the used MJF powder is a critical step in ensuring a smooth recycling process. Before loading the powder into the 3devo Filament Maker, it is essential to ensure that the powder is clean and free of any large contaminants that could interfere with the recycling process. Cleaning the powder involves sieving it to remove any large particles and ensuring no moisture is present, as it can lead to extrusion defects.
Contaminants in the MJF powder can cause issues during the filament extrusion process, such as clogging the machine or producing filament that does not meet quality standards. Therefore, sieving and drying the powder are crucial. This step not only prepares the material for efficient extrusion but also ensures the produced filament’s quality and consistency.
3. Load Powder into Filament Maker
Once the MJF powder is prepared and free from contaminants, the next step is to place the cleaned and prepared MJF powder into the feed hopper of the 3devo Filament Maker. The loading process should be done carefully to prevent any spillage and to ensure an even feed of the powder into the extrusion system.
Proper loading of the powder is essential to avoid interruptions during the extrusion process. An even and consistent feed ensures the filament produced is uniform in diameter and quality, which is critical for subsequent 3D printing applications.
4. Customize Machine Settings
Configuring the machine settings is the next critical step. This involves setting the screw speed, cooling settings, and extrusion speed according to the desired filament specifications. These parameters are essential for maintaining consistent filament quality and ensuring the efficient operation of the 3devo Filament Maker.
Customization of the machine settings allows operators to control the extrusion process meticulously. For instance, adjusting the screw speed ensures even distribution and uniform melting of the powder. Similarly, precise cooling settings prevent the filament from becoming too brittle or retaining excess heat. The extrusion speed needs careful adjustment, as a slower speed allows more time for cooling, helping maintain a consistent filament diameter.
5. Initiate Extrusion Process
With the machine settings configured, it’s time to initiate the extrusion process. Start the extrusion process by activating the 3devo Filament Maker and feeding the MJF powder through the extruder. This marks the beginning of converting the powder into reusable filament.
The extrusion process transforms the MJF powder into a continuous strand of filament, which is then cooled and solidified. It’s essential to monitor the process continually to ensure everything functions correctly. Any issues during this phase can be addressed promptly to prevent defects in the filament.
6. Monitor Quality Control Data
Quality control is paramount in the filament production process. While the extrusion is ongoing, it’s crucial to keep an eye on key data points such as screw speed, cooling temperatures, and extrusion speed. These parameters help ensure high-quality filament production and allow for quick adjustments if any inconsistencies arise.
Effective quality control involves monitoring data in real-time, identifying deviations from the set parameters, and making necessary corrections to maintain the desired filament characteristics. This step helps produce filament that meets industrial standards and is suitable for high-quality 3D printing applications.
7. Adjust Settings as Needed
Throughout the extrusion process, adjustments to the settings may be necessary to maintain consistent filament diameter and quality. Operators should be prepared to tweak the extrusion speed and cooling settings based on real-time data and observations to ensure the filament produced meets the required specifications.
Fine-tuning the process parameters is a continuous task that significantly influences the filament’s final quality. This adaptability ensures that any issues are quickly addressed, and the filament produced is consistent and high in quality, reducing the likelihood of defects in subsequent 3D printing projects.
8. Collect and Spool Filament
Once the extrusion process is complete, the produced filament needs to be collected and wound onto spools for storage and future use. This step involves guiding the filament onto spools in a controlled manner to prevent tangling and ensure it is neatly stored, making it easier to use later on.
Spooling the filament correctly is essential for efficient use in 3D printers. Properly wound filament ensures smooth feeding during 3D printing, reducing downtime and improving the overall printing experience. This step also allows for easier handling and transport of the filament.
9. Inspect Finished Filament
After the filament is spooled, it is essential to examine it to ensure it meets quality standards before using it in 3D printing. Inspection involves checking the filament diameter for consistency, ensuring there are no visible defects, and testing a sample to see if it performs as expected in a 3D printer.
Quality inspection ensures that only high-quality filament is used for 3D printing, reducing the risk of print failures and ensuring the final printed objects meet the desired specifications. This step is crucial for maintaining the integrity of the printing process and achieving optimum results.
10. Implement Waste Management Procedures
Preparing used Multi Jet Fusion (MJF) powder is vital to ensure a seamless recycling process. Prior to loading this powder into the 3devo Filament Maker, it is crucial to verify that the powder is clean and devoid of large contaminants that could interfere with recycling. This means sieving the powder to remove any large particles and making sure there is no moisture, which can cause flaws during extrusion.
Contaminants in MJF powder can lead to numerous problems during filament extrusion, like clogging the machine or producing subpar filament. Hence, sieving and drying the powder are essential steps. These measures not only prepare the material for efficient extrusion but also guarantee the quality and consistency of the filament produced.
Additionally, after sieving and drying, it’s recommended to store the prepared powder in an airtight container to maintain its dryness and cleanliness until it is used. Environmental factors such as humidity can affect the quality of both the powder and the resulting filament. Therefore, proper storage is a key aspect of the preparation process.
To further ensure high-quality filament, it’s beneficial to periodically maintain and clean the 3devo Filament Maker, removing any residues or contaminants that could impact performance. Following these steps meticulously will contribute to a more efficient recycling process and superior filament output, essential for achieving the highest standards in 3D printing projects.
