‘Closed Loop’ 3D Printing from waste packaging: How to Case Study

Abstract

During the period 12/12/13 – 25/04/14, Co-oproduct CIC lead a project in collaboration with Nestle’ Research and NTU to explore the feasibility of a small scale 'Closed Loop' 3D Printing solution, using recycled/waste plastic as feedstock for educational use.

With support from the Technology Strategy Board, Nestle’, UnLTD and Nottingham Trent University; we carried out R&D work and built our own 1st stage prototype 3D printing system, which was capable of printing from recycled plastic waste.

We made various developments and innovations for the successful production of printable filament from recycled Polypropylene (PP) packaging/waste. To our knowledge, we are the first to document/publish printed objects from this particular waste packaging polymer, which may otherwise go to landfill.

The solution aimed to maximise the embodied energy of ‘waste’ polymers, through clever re-use of them, thereby reducing carbon emissions through the on-site 'closed loop' innovation. In addition, we wanted to reduce water consumption, since the most popular feedstock used is PLA and has a very high water footprint. We commissioned an independent report by 3DP/AM experts Econolyst to evaluate our work by carrying out Life Cycle Assessments and Market Research.

According to our independent LCA (March 2014), our proposed closed loop reuse of PP packaging via 3D Printing, potentially uses 20 MJ less energy and 50% less water per 1Kg than the current, most popular 3D printing solution.

Additionally, our report estimated that there is a market for some 10,000 3D printing machines within UK industry, 4,000 within UK secondary schools and some 1,400 within Universities and Colleges, giving a total market opportunity of 15,400 units.

In April 2015, for our work on this project, we were declared winners of the ‘Responsible Waste Management’ category of the RSA City of London Sustainable City Awards and runners up for the ‘Resource Conservation’ category.

The majority of the knowledge required for the successful development of the solution was acquired without cost, via global community sharing networks and forums. Most of this information was new to the team and all major developments were achieved through 'hands-on' practice, crafting and experimentation. This is our story.