Terephthalate (PET) Filament Extruder- Plastic

Recycling

Prepared by:

Fatima Osamah Al-Nahari 202270039

Maha Jamal Al-Sharabi 202270043

Afaf Abdulbaqi Al-Qadasi 202270153

Hala Hesham Al-Kebsi 202273003

Supervised by:

Prof. Abdullah Thaiban

REPUBLIC OF YEMEN

SANA'A UNIVERSITY FACULTY OF ENGINEERING

MECHATRONICS ENGINEERING DEPARTMENT
Contents
ABSTRACT........................................................................................................................................ 3

1. INTRODUCTION: ......................................................................................................................... 4

2. OBJECTIVES: ................................................................................................................................ 5

3. SYSTEM REQUIREMENTS: ........................................................................................................ 5

3.1 Hardware Selection: ...................................................................................................................... 5

3.2 Software Selection: ..................................................................................................................... 14

4. PROCEDURE: .............................................................................................................................. 14

5. SYSTEM ANALYSIS: ................................................................................................................. 16

5.1 Hardware Analysis:..................................................................................................................... 16

5.2 Software Analysis: ...................................................................................................................... 18

5.3 Mechanical Analysis: .................................................................................................................. 18

5.3.1 Stress and Strain Analysis ........................................................................................................ 18

5.4 Control Analysis: ........................................................................................................................ 24

5.5 Electrical Analysis: ..................................................................................................................... 56

6. DISCUSSION: .............................................................................................................................. 57

7. RECOMMENDATION: ............................................................................................................... 59

7.1 Future Developments: ................................................................................................................. 60

7.2 Challenges:.................................................................................................................................. 61

8. CONCLUSION: ............................................................................................................................ 62

9. REFERENCES: ............................................................................................................................ 63

10. APPENDICES: .......................................................................................................................... 64

Appendix (1) Arduino Code ............................................................................................................. 65

 ABSTRACT

Polyethylene Terephthalate (PET) Filament Extruder- Plastic Recycling

Plastic pollution is one of the most emblematic environmental issues of our century; each year billions
of tons of plastic waste are irreversibly deposited into landfills, oceans, and natural environments all
around the world. A part of this waste is thermoplastics, thermally recyclable plastics that can be utilized
in the manufacture of new 3D printing filaments. For instance, polyethylene terephthalate is widely
consumed in water bottles, food packaging, and textiles. This paper aims to provide an exhaustive
account of PET recycling into 3D printing filament.

The purpose of this project was to develop, construct, and test a small-scale PET filament extruder
system that can recycle post-consumer plastic waste to produce a feedstock material suitable for compact
3D printers. To produce FDM-style 3D printing filaments, the extruder system was intended to melt and
extrude shredded PET plastic bottles into a strong and high-quality filament of the correct size.

Some of the key design considerations for the extruder included the screw geometry, heating system,
and filament winding mechanism. Given that the extruder underwent some minor changes after each
design process, the final extruder prototype proved to be capable of extruding 1.7 mm PET filaments
with high consistency in dimensions, mechanical behavior, and aesthetic appearance after extensive
testing. Moreover, recycled PET filament samples were tests with some found to exhibit favorable
performance similar to commercial virgin PET filaments when 3D printed into test parts.

Overall, the demonstrated technical feasibility of converting waste plastic into a valuable 3D printing
feedstock material using a small-scale in-house extruder marks a significant milestone in the
development of distributed, localized plastic recycling systems. Additional improvements in the
extruder’s design and processing settings could widen and stabilize the filament while increasing the
production rate. Finally, the possibilities of simple and inexpensive recycling technologies to curb plastic
pollution while also serving as an accessible source of 3D printing material are showcased by the project.

1. INTRODUCTION:
Plastic pollution is one of the most critical environmental problems of the contemporary world.
Currently, people generate over 380 million tons of plastic waste each year worldwide, with most of it
being dumped into landfills, oceans, and other natural habitats. The increasing amount of plastic waste
threatens ecosystems, wildlife, and human health.

One of the main drivers of this avalanche of plastic is an enormous consumption of disposable plastic
products which presents various forms, namely water bottles, but also food containers, wrapping, and
packaging materials. Even though many of these items are theoretically recyclable, recycling rates are
dismal in many places, oscillating at below 10-20% in many regions. The lack of efficient systems of
garbage collection, the contamination of items, and the amounts of plastic are contributing to a lack of
effective recycling.

One promising approach to addressing the plastic waste problem is to develop new technological
solutions for mechanical recycling of common thermoplastics, like polyethylene terephthalate (PET).
PET is one of the most widely used and recyclable plastic resins, with major applications in beverage
bottles, food packaging, clothing, and various consumer products. Recycling PET waste into new
products, such as 3D printing filament, can help divert this material from landfills and oceans while also
providing a source of sustainable raw material.

This project aimed to design, build, and test a small-scale PET filament extruder system capable of
converting post-consumer plastic waste into a feedstock material suitable for desktop 3D printing. By
developing a distributed, localized recycling technology, the goal was to demonstrate the feasibility of
in-house plastic recycling to produce 3D printing materials and reduce plastic waste at the community
level.

The following sections describe the design, fabrication, and testing of the PET filament extruder
prototype, as well as an evaluation of the performance and properties of the recycled PET filament
produced. The results of this project provide insights into the technical and practical considerations for
small-scale plastic recycling systems and their potential impact on the circular economy.
 2. OBJECTIVES:

1. Design and build a small-scale, low-cost extruder system capable of converting post-consumer PET
plastic waste into 3D printing filament.

2. Optimize the extruder design and processing parameters to produce PET filament with the
appropriate diameter, mechanical properties, and surface quality for use in desktop FDM-style 3D
printers.

3. Evaluate the performance and properties of the recycled PET filament produced by the extruder
system, including conducting mechanical testing and 3D printing trials.

4. Assess the technical feasibility and potential scalability of using a distributed, in-house PET
recycling system to reduce plastic waste and provide a local source of 3D printing materials.

5. Identify key design considerations, challenges, and areas for future improvement in the development
of small-scale plastic recycling technologies.

3. SYSTEM REQUIREMENTS:

3.1 Hardware Selection:

• 12V 10A DC Power Supply

• Plastic bottles

• Razor blades

• Connection wires

• Bolts, screws, washers and plastic strap cables.

• NEMA 17 Stepper Motor:

The NEMA 17 stepper motor will be the primary driver for the extruder screw, providing precise control
over the filament extrusion process. This type of stepper motor is widely used in 3D printing and other
additive manufacturing applications due to its compact size, high torque, and accurate positioning
capabilities. The selected NEMA 17 stepper motor should have a holding torque of at least 40 N·cm and
a step angle of 1.8 degrees, which is a common and versatile configuration. These specifications ensure
that the motor can provide the necessary force to extrude the PET filament while maintaining tight
control over the filament diameter and flow rate.

A stepper motor is an electromechanical device that transforms electrical pulsations into discrete
mechanical motions, and it is a type of synchronous motor that has a high torque and low speed. The
rotor rotates in discrete form by applying a sequence of electric pulses that cause the rotations, where
the direction of the shaft rotation is directly correlated with the order of the applied pulses. Furthermore,
the rotating speed and rotation angle are both based on the input pulses, considering that the position
holding must occur without consuming energy.

Quick Specs:

• Step moment angle: 1.8 ° Current: 0.84A

• Resistance: 5.75 Ohm Inductance: 9.3mH
• Static torque: 28N.cm 
• Shaft diameter: 5mm
• Motor weight: 300g Body length: 40mm
• NEMA 17
• Model  42HB34F08AB
• Rated power: 200 (W)
• Product Type: 2-phase hybrid stepper motor
• Rated voltage: 4-12 (V)
• Rated current: 1.25 (A)
• Rated speed: 0-900 (rpm)
• Rated torque: 3.5 (NM)
• Dimensions: 42 x 42 x 40 mm

Mathematical representation:
• LM298 Motor Driver:

To control the NEMA 17 stepper motor, an LM298 dual H-bridge motor driver will be used. The LM298
is a popular and widely available motor driver module that can provide up to 2 amperes of current per
channel, which is sufficient for the selected stepper motor. The LM298 driver will be integrated with the
Arduino Uno microcontroller, allowing for seamless speed and direction control of the extruder screw.
This integration will enable precise control over the filament extrusion process, ensuring consistent and
reliable filament production.

ARD2
ON
Reset BTN

SDM1
www.TheEngineeringProjects.com

STEPPER DRIVER
AREF

13
PB5/SCK
12 A 1
PB4/MISO IN1
RESET 11 IN2 2
~ PB3/MOSI/OC2A
10 IN3 B 3
~ PB2/OC1B
9 IN4 4
~ PB1/OC1A
8 IN5 C 5
PB0/ICP1/CLKO
IN6
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ATMEGA328P-PU

IN7
1121

7
ANALOG IN

PD7/AIN1 +88.8
6 STEPPER DRIVER
A0 ~ PD7/AIN1
5
PC0/ADC0 ELECTRONICSTREE.COM
A1 ~ PD5/T1/OC0B
4
PC1/ADC1
A2 PD4/T0/XCK
3
PC2/ADC2 - +
A3 ~ PD3/INT1/OC2B
2
PC3/ADC3 PD2/INT0
A4 1
PC4/ADC4/SDA PD1/TXD
A5 0
PC5/ADC5/SCL PD0/RXD

ARDUINO UNO RV1

1k

32%

RXD

TXD

RTS

CTS

• DC to DC Solid State Relay (SSR):

The DC to DC solid state relay (SSR) will be used to control the power supply to the heater elements in
the extruder's heat end. The SSR will interface directly with the PID Temperature Controller, allowing
for precise temperature regulation of the heat end. The selected SSR should have a voltage rating of 12V
and a current rating of at least 10A, which should be sufficient to handle the heating load required for
the PET filament extrusion process. The use of a solid-state relay instead of a mechanical relay ensures
fast switching, high reliability, noise, and reduced maintenance requirements.
• Arduino UNO R3 Board

The Arduino Uno will serve as the main microcontroller unit for the extruder system. It will be
responsible for coordinating the various hardware components, including the stepper motor control.
.This versatile and widely-used microcontroller platform will provide a reliable and easy-to-program
solution for the overall control and integration of the extruder system.

• Hot End Extruder:

The hot end extruder is the crucial component responsible for melting and extruding the PET filament.
It consists of several key parts: a heating element, typically a cartridge heater or ceramic element, that
can reach the high temperatures required to liquefy the PET material (around 100-120°C); proper
insulation around the heating element to minimize heat loss and ensure efficient heat transfer to the PET;
a nozzle, the final component that shapes the molten PET into the desired filament diameter, with the
design of the nozzle's diameter and length carefully optimized to achieve the target filament size and
flow characteristics; and a heat block, the metal housing that holds the heating element, insulation, and
nozzle together, ensuring a secure and well-integrated hot end assembly.

• PID Temperature Controller:

The PID (Proportional-Integral-Derivative) temperature controller is the brain of the hot end temperature
regulation system. Its key functions include: temperature measurement, where it receives feedback from
the thermocouple installed in the hot end; temperature regulation, using the PID algorithm to precisely
adjust the power to the heating element to maintain the desired temperature set point; auto-tuning
capabilities, which allow for easy optimization of the PID parameters to achieve the best temperature
control performance; and interfacing with the Arduino Uno microcontroller, enabling digital control and
monitoring of the hot end temperature.

• Thermocouple Sensor:

The thermocouple sensor is a critical component in the temperature control system of the PET filament
extruder. This sensor is responsible for providing real-time feedback on the temperature of the hot end,
where the PET material is being melted and extruded. The specific type of thermocouple selected for
this project is a Type K thermocouple, which is capable of measuring temperatures up to 1260°C, well
beyond the range required for PET extrusion (typically around 100-120°C). The thermocouple is
strategically positioned within the heat block of the hot end, as close to the molten PET as possible, to
ensure accurate temperature measurement. This close proximity allows the thermocouple to quickly
detect and respond to any changes in the melt temperature, enabling the PID temperature controller to
make precise adjustments to maintain the desired set point. The fast response time of the thermocouple
is crucial for the effective operation of the closed-loop temperature control system.

• Cooling Fan:

In addition to the hot end components, the PET filament extruder system also requires a cooling
mechanism to ensure the proper solidification and formation of the extruded filament. This is achieved
through the use of a cooling brushless fan, which is positioned to direct a stream of air onto the extruded
PET filament as it emerges from the nozzle. The cooling fan serves two main purposes:

1. Filament Solidification: The cooling air flow helps to quickly solidify the molten PET
filament as it exits the nozzle, preventing it from sagging or deforming and ensuring the
desired filament diameter and shape are maintained.

2. Heat Dissipation: The cooling air flow also helps to dissipate the heat from the hot end,
preventing heat buildup in the surrounding components and ensuring the overall system
remains within its optimal operating temperature range.

• Optical Infrared Encoder Module:

The Optical Infrared Encoder Module plays a vital role in the filament extruder of this PET plastic bottle
recycling system, working in tandem with a stepper motor to precisely control the extrusion process.
The encoder module, consisting of an infrared LED and photodetector, monitors the rotation of the
extruder's drive shaft, generating electrical pulses that correspond to the speed of motion. This encoder
data is fed into the system's control electronics, which use it to expertly regulate the stepper motor's
speed and, in turn, the rate of plastic extrusion. This closed-loop control enables the production of PET
filament with extremely consistent diameter and quality - a necessity for meeting the stringent
requirements of applications like 3D printing, where the recycled plastic material must perform to the
same high standards as virgin feedstock.

• Self- designed PID:

As in any PID system we need to define a final process, in our case will be the final temperature that we
will achieve. In order to control this temperature, we will need a feedback. So, any PID control will have
some sort of feedback. In our case, that feedback is made using a K type thermocouple that will measure
the real temperature of the system.

This type of control will also need a setpoint, which in our case is the desired temperature. The system
will make the difference between the desired value and the feedback from the output (error), and using
3 constants, the proportional, the integral and derivative, we can change the output according to the
feedback.

So, if we want the heating block to have exactly 100 degrees what we will do first is apply power to it.
This will start heating up. By the time it reaches the setpoint value, which in this case is 100 degrees,
the feedback will inform that to the PID control, and this will start lowering the power applied to the
heating element, and in our example that will be made using a PWM signal applied to a MOSFET that
will control the voltage that goes to the heating element inside the block.
So, it is obvious, if the real temperature is higher than the setpoint, we lower the power value, if the real
temperature is lower than the setpoint, well, we increase the power till it reaches the desired value.
• 3D printed parts.
Table 1 printed parts
3.2 Software Selection:

• SolidWorks
• Arduino IDE
• PID Temperature Controller
• Matlab

4. PROCEDURE:

a) Plastic Feedstock Preparation:

• Collect used PET plastic bottles and other PET waste.

• Clean and dry the PET plastic to remove any contaminants.

• Shred or granulate the PET plastic into small flakes or tapes using the cutter made.

b) Extruder Assembly and Setup:

• Construct the main extruder body, including the hopper, barrel, and die.

• Install the extruder screw, drive motor, and heating elements.

• Connect the necessary sensors, controls, and supporting mechanisms.

• Integrate a CH902FK04-M*AN PID temperature controller to maintain the extruder barrel

temperature.

c) PID Controller and SSR Integration:

• Connect the PID temperature controller output to the input of a solid-state relay (SSR).
• Wire the SSR in series with the extruder heater element, ensuring the correct polarity and
voltage ratings.

d) Configure the PID controller settings, such as the proportional, integral, and derivative gains, to
optimize temperature control.
e) Mathematical and Experimental Modeling:

• Develop a mathematical model of the extruder system, including the thermal dynamics,
screw dynamics, and material flow.

• Conduct experimental tests to characterize the system behavior and validate the mathematical
model.

• Use MATLAB to implement the mathematical model and simulate the system performance.

e) System Design, Implementation, and Analysis:

• Design open-loop and closed-loop control strategies for the extruder system using MATLAB.

• Implement the control algorithms on the physical extruder setup, including the PID
temperature controller and SSR.
 • Analyze the system performance in both open-loop and closed-loop configurations,
evaluating factors such as stability, response time, and disturbance rejection.

f) Extruder Calibration and Operation:

• Configure the PID temperature controller to accurately maintain the extruder barrel at 100°C,
the optimal temperature for PET melting and flow.

• Adjust the screw speed and other processing parameters to achieve consistent filament
extrusion.

• Monitor the extruder performance and make any necessary adjustments to maintain the target
temperature and filament quality.

g) Filament Winding and Take-up:

• Guide the extruded PET filament through a cooling system.

• Use a motorized filament winding mechanism to collect the filament onto a spool.

• Ensure the filament maintains the desired diameter and surface quality.

h) Filament Testing and Evaluation:

• Measure the diameter, roundness, and surface finish of the recycled PET filament.

• Conduct mechanical testing, such as tensile and flexural tests, to assess the filament
properties.

• 3D print test parts using the recycled PET filament and evaluate the print quality.

5. SYSTEM ANALYSIS:

5.1 Hardware Analysis:

1. Bottle Cutting Mechanism:

 • Analyze the cutting blade configuration, including the shape, thickness (1mm), and
sharpness, to optimize the cutting performance and minimize material waste.
• Evaluate the blade materials and coatings to ensure durability, corrosion resistance, and
consistent cutting quality over the lifetime of the system.

2. Extruder Mechanism:
• Optimize the extruder screw and barrel design, materials, and clearances to improve material
transport, melting, and compression.
• Determine the torque and power requirements for the extruder screw drive, and select an
appropriate motor and drivetrain.
• Design the heating system to maintain a uniform melt temperature profile along the barrel.
3. Filament Cooling and Take-up:
• Evaluate the cooling system performance, including air/water flow, temperatures, and
geometries, to effectively solidify the extruded filament.
• Design the filament puller system to maintain uniform tension and winding patterns, while
considering the dynamic behavior of the filament.

4. Structural Integrity:
• Analyze the structural loads and stresses on the extruder frame, supports, and mounts using
techniques like finite element analysis.
• Assess the potential for vibrations and resonances, and implement vibration-damping
strategies.

5. Thermal Management:
• Develop a comprehensive thermal model to optimize temperature distribution and minimize
energy losses.
• Design effective insulation and cooling systems to maintain optimal operating temperatures.

6. Material Compatibility:
• Evaluate the compatibility of extruder components with the PET polymer material,
considering wear and durability.
• Incorporate design features to enhance the long-term performance and ease of maintenance.
 7. Safety and Ergonomics:
• Implement appropriate safeguarding mechanisms and comply with relevant safety standards.
• Consider the ergonomics of the extruder system to enhance the operator experience and
reduce the risk of errors or injuries.

5.2 Software Analysis:

a) Arduino Code: (See Appendix 1)

• This code is used to control the stepper motor with L298 driver.

b) PID Temperature Control Integration:

• Seamlessly integrate the CH902FK04-M*AN PID temperature controller into the overall
process control system of the extruder.
• Ensure the control software can properly communicate and exchange data with the PID
controller, leveraging the appropriate communication protocols (e.g., Modbus, RS-485).
• Develop robust parameter tuning and optimization routines to configure the PID controller
for optimal temperature regulation performance across the various heating zones of the
extruder.

c) Sensor Integration and Calibration:

• Integrate the temperature sensors (e.g., thermocouples) that provide feedback to the PID
controller into the overall data acquisition system.
• Implement comprehensive sensor calibration and diagnostics routines to ensure the accuracy
and reliability of the temperature measurements.
• Establish alarm and fault handling mechanisms to promptly detect and respond to any sensor
failures or drift in the temperature readings.

5.3 Mechanical Analysis:

5.3.1 Stress and Strain Analysis

The key printed parts in the gearbox that we'll need to analyze are:

1. Gears
2. Shafts
3. Bearings

Gear Stress Analysis:

1. Bending Stress: The gear teeth experience bending stress as they engage with the mating gear,
which is highest at the root of the gear teeth.
2. Contact Stress: The meshing gear teeth also experience high compressive contact stress at the
pitch point, which can lead to surface fatigue and pitting.
3. Torsional Stress: The gear body experiences torsional stress from the transmission of torque from
the motor to the extruder screw.

Shaft Stress Analysis:

1. Bending Stress: The shafts supporting the gears experience bending stress from the radial loads of the
gears.
2. Torsional Stress: The shafts also experience torsional stress from the transmission of torque.
3. Shear Stress: At the bearing locations, the shafts experience shear stress from the support reactions.

Bearing Stress Analysis:

1) Hertzian Stress: The bearings experience high compressive Hertzian stress at the ball/race
contact points.
2) Fatigue Stress: The bearing races and balls also experience cyclic stresses that can lead to fatigue
failure over time.

Strain Analysis:
1) Gear Strain: The gear teeth may experience small amounts of bending and compressive strain,
which can lead to gear tooth deformation and reduced contact ratio over time.
2) Shaft Strain: The shafts may experience torsional and bending strain, which can affect the
alignment and clearances of the gearbox components.
3) Bearing Strain: The bearings may experience small amounts of radial and axial strain, which can
impact the preload and running clearances.
To quantify these stresses and strains, you would need to perform detailed finite element analysis (FEA)
simulations of the gearbox components, considering factors such as:

- Gear geometry and material properties

- Shaft dimensions and material properties
- Bearing size, type, and material properties
- Loading conditions (torque, radial/axial loads, etc.)
- Lubrication and friction effects

The results of the FEA would allow you to identify the critical stress and strain points, and then
optimize the design of the printed gearbox
components accordingly.

Additionally, you may want to consider factors

like thermal effects, fatigue life, and safety
factors to ensure the long-term reliability and
performance of the gearbox.

The design and operation of the PET plastic bottle filament extruder also involves complex stress and
strain considerations to ensure the structural integrity and reliable performance of the system. Some
key aspects of the stress and strain analysis for this project include:

• Barrel and Screw Stresses:

The extruder barrel and screw are subjected to significant mechanical stresses due to the high pressures
and shear forces involved in the extrusion process. Finite element analysis (FEA) can be used to model
the stress distribution within the barrel and screw, accounting for factors such as material properties,
geometry, and operating conditions. Ensuring that the peak stresses in the barrel and screw remain within
the material's yield strength is crucial to prevent deformation or failure.

• Die and Adapter Stresses:

The die and adapter components, which shape the molten polymer into the desired filament, experience
localized high-stress regions due to the rapid change in flow geometry. FEA can be employed to analyze
the stress distribution in the die and adapter, considering factors like material properties, thermal
gradients, and flow-induced stresses. Optimization of the die and adapter design can help minimize stress
concentrations and ensure the structural integrity of these critical components.

• Thermal Stresses:
The temperature variations throughout the extruder system, from the heated barrel to the cooling die,
can lead to significant thermal stresses. Thermal expansion and contraction of the various components
must be accounted for to prevent issues like warping, cracking, or dimensional instability. Coupled
thermal-structural analysis can be used to model the thermal stresses and ensure that they remain within
acceptable limits.

• Bearing and Coupling Stresses:

The rotating screw and drive system components, such as bearings and couplings, experience cyclic and
dynamic stresses that must be analyzed. Fatigue analysis can be performed to estimate the service life
of these components and ensure that they can withstand the anticipated loading conditions. Appropriate
design and selection of bearings, couplings, and other rotating elements are crucial to prevent premature
failure.

• Frame and Support Structure Stresses:

The overall frame and support structure of the extruder system must be designed to withstand the static
and dynamic loads imposed by the various components. FEA can be used to evaluate the stress
distribution in the frame and support structure, considering factors like weight, vibration, and external
loads. Optimization of the frame and support design can help minimize stress concentrations and ensure
the overall stability and reliability of the system.

5.4 Control Analysis:

%%openloop analysis
sys=tf

sys =
From input "u1" to output "y1":
4.961e04
-----------------------
s^2 + 4340 s + 3.402e04

Name: tf
Continuous-time identified transfer function.

Parameterization:
Number of poles: 2 Number of zeros: 0
Number of free coefficients: 3
Use "tfdata", "getpvec", "getcov" for parameters and their uncertainties.

Status:
Estimated using TFEST on time domain data "olsys".
Fit to estimation data: 75.59% (stability enforced)
FPE: 3463, MSE: 2930

Model Properties

linearSystemAnalyzer(tf)

S=stepinfo(tf)

1
S = struct with fields:
RiseTime: 0.2797
TransientTime: 0.4983
SettlingTime: 0.4983
SettlingMin: 1.3186
SettlingMax: 1.4571
Overshoot: 0
Undershoot: 0
Peak: 1.4571
PeakTime: 0.9323

[wn,zeta,p] = damp(tf)

wn = 2×1
103 ×
0.0079
4.3317
zeta = 2×1
1
1
p = 2×1
103 ×
-0.0079
-4.3317

%%closed loop analysis

H= feedback(sys,1)

H =

From input "u1" to output "y1":

4.961e04
-----------------------
s^2 + 4340 s + 8.363e04

Continuous-time transfer function.

Model Properties

linearSystemAnalyzer(H)

2
S2=stepinfo(H)

S2 = struct with fields:

RiseTime: 0.1135
TransientTime: 0.2023
SettlingTime: 0.2023
SettlingMin: 0.5363
SettlingMax: 0.5928
Overshoot: 0
Undershoot: 0
Peak: 0.5928
PeakTime: 0.3783

[wn,zeta,p] = damp(H)

wn = 2×1
103 ×
0.0194
4.3202
zeta = 2×1
1
1
p = 2×1
103 ×
-0.0194
-4.3202

3
4
4
5.5 Electrical Analysis:

Electrical Analysis for the PET Plastic Bottle Filament Extruder:

• Motors Used and Their Internal Composition:

For the PET plastic bottle filament extruder, the key motors used are stepper motors. Stepper motors are
a type of brushless DC motor that can provide precise control over angular position, velocity, and
acceleration. The internal composition of a stepper motor typically includes the following components:

a) Stator: The stator consists of a series of electromagnetically charged coils arranged around
the motor's central axis. These coils create a rotating magnetic field when energized, which
interacts with the rotor to produce torque and rotation.

b) Rotor: The rotor is a permanent magnet that aligns itself with the rotating magnetic field
generated by the stator coils. The rotor's angular position is directly proportional to the
sequence of electrical pulses applied to the stator coils.

c) Drive Electronics: Stepper motors require a specialized drive circuit to control the sequence
and timing of the electrical pulses applied to the stator coils. This drive circuit, often based
on a microcontroller or driver IC, is responsible for precisely controlling the motor's step
angle, speed, and torque.
The theory of operation for a stepper motor involves the sequential energization of the stator coils, which
creates a rotating magnetic field. This magnetic field interacts with the permanent magnet rotor, causing
it to align and rotate in discrete steps. By controlling the timing and sequence of the electrical pulses,
the stepper motor can be precisely positioned and rotated in a controlled manner.

• Arduino Connection and Electrical Equations:

In the PET plastic bottle filament extruder, the stepper motors used for the extruder screw and other
critical components are controlled by an Arduino microcontroller. The Arduino is connected to the
stepper motor drive electronics, which typically includes a stepper motor driver IC, such as the A4988
or DRV8825.
The key electrical equations involved in the Arduino-stepper motor connection are:

a. Step Angle (θ): The step angle is the angular displacement of the rotor per electrical pulse
applied to the stator coils. For a typical stepper motor, the step angle is given by θ = 360°
/ (number of steps per revolution).

b. Step Rate (ω): The step rate, or angular velocity, is the number of steps per second applied
to the stepper motor. The step rate is controlled by the timing of the electrical pulses sent
from the Arduino to the stepper motor driver.

c. Torque (T): The torque generated by the stepper motor is dependent on the current
flowing through the stator coils. The Arduino, in conjunction with the stepper motor
driver, can control the current and thus the torque output of the motor.

The Arduino's firmware and control algorithms are responsible for generating the appropriate sequence
of electrical pulses to the stepper motor driver, based on the desired step angle, step rate, and torque
requirements of the extruder system. This precise control over the motor's operation is crucial for
ensuring the consistent and reliable performance of the PET plastic bottle filament extruder.

• Electrical System Integration and Considerations:

In addition to the stepper motor control, the electrical system for the PET plastic bottle filament extruder
must also consider the integration of other components, such as:
 a) Heating Elements: The extruder barrel and die components require precise temperature
control, which is typically achieved using heating elements and temperature sensors
integrated into the system.

b) Sensor Inputs: The extruder system may incorporate various sensors, such as pressure
transducers, flow meters, or temperature sensors, to monitor the extrusion process and
provide feedback to the control system.

c) Safety Interlocks: Electrical safety features, such as emergency stop switches, overload
protection, and grounding systems, must be implemented to ensure the safe operation of the
extruder.

d) Power Distribution: The electrical system must provide the appropriate power supply and
distribution to all the components, including the motors, heaters, sensors, and control
electronics.

By carefully designing the electrical system, including the stepper motor control, sensor integration, and
safety features, the PET plastic bottle filament extruder can be operated reliably and efficiently, ensuring
the consistent production of high-quality filament.

6. DISCUSSION:

The PET filament extruder is a critical component in the recycling and repurposing of PET plastic waste
for 3D printing applications. By converting used PET bottles and other PET packaging into a consistent
filament, this system allows for the sustainable reuse of a common plastic material.

One of the key aspects of the extruder's operation is the temperature control provided by the PID
controller and solid-state relay (SSR). Maintaining the extruder barrel at the optimal temperature of
100°C is crucial for achieving the proper melting and flow characteristics of the PET material. The PID
controller's ability to precisely regulate the temperature, and the SSR's fast switching capabilities, ensure
that the barrel temperature remains stable despite changes in feedstock, screw speed, or other process
variables.
The mathematical and experimental modeling steps are important for developing a deep understanding
of the system's thermal dynamics, material flow, and other critical behaviors. By creating a validated
simulation model in MATLAB, the extruder's performance can be optimized through adjustments to the
control algorithms, screw design, and other parameters before committing to physical changes.

The open-loop and closed-loop control strategies explored in the system design and analysis phase allow
for a comprehensive evaluation of the extruder's stability, responsiveness, and disturbance rejection
capabilities. This can help identify the most appropriate control approach for ensuring consistent
filament quality and productivity.

During the actual operation of the extruder, the continuous monitoring and adjustment of parameters like
temperature, screw speed, and filament properties are essential. By making real-time tweaks to the
process, the operator can maintain tight control over the filament characteristics, such as diameter,
roundness, and surface finish.

The final testing and evaluation of the recycled PET filament is crucial for verifying its suitability for
3D printing applications. Mechanical testing, print quality assessments, and other analyses can provide
valuable insights into the filament's performance and limitations, informing further refinements to the
extruder system and process.

Overall, the PET filament extruder represents an important technology for transitioning towards a more
circular economy, where plastic waste is repurposed into useful materials rather than ending up in
landfills or the environment. By leveraging advanced control systems and data-driven optimization, this
extruder can play a key role in enabling the sustainable production of high-quality 3D printing filaments.

7. RECOMMENDATION:

7.1 Future Developments:

As the PET filament extruder system continues to evolve, there are several potential future developments
and improvements that could enhance its capabilities and efficiency:

a) Automated Feedstock Preparation:

One of the challenges in this project is the need to integrate automated shredding, sorting, and cleaning
systems for the PET plastic waste to streamline the feedstock preparation process. Developing advanced
sensor-based systems to identify and remove any contaminants or non-PET materials from the feedstock
is also crucial to ensure the quality and consistency of the raw material.

b) Intelligent Process Control:

Another challenge is the implementation of machine learning algorithms to adaptively tune the PID
controller settings based on real-time process data and historical performance. Integrating predictive
maintenance models to anticipate and prevent potential equipment failures or performance issues, as
well as exploring the use of digital twins and advanced simulations to optimize the extruder's design and
control strategies, are also important considerations.

c) In-Line Quality Monitoring:

Incorporating advanced sensors and vision systems to continuously monitor the extruded filament's
properties, such as diameter, roundness, and surface finish, is a key challenge. Developing closed-loop
control algorithms that can automatically adjust processing parameters to maintain the desired filament
quality, and integrating real-time data analytics to track and optimize the overall production yield and
consistency, are also critical aspects of this project.

d) Multiheaded Extrusion:

Designing extruder systems with multiple die heads to simultaneously produce multiple filaments,
increasing the overall production capacity, is a complex engineering challenge. Exploring the feasibility
of independent temperature and speed control for each extrusion head to further enhance filament quality
and consistency is another aspect that requires careful consideration.

e) Recycled Polymer Blending:

Investigating the integration of additional recycled polymers, such as PLA or ABS, into the PET
feedstock to create custom-tailored filament blends is a challenge that requires the development of
advanced mixing and compounding systems to ensure homogeneous distribution of the polymer
components.

f) Filament Annealing and Surface Treatment:

Implementing post-extrusion annealing or heat treatment processes to improve the mechanical properties
and dimensional stability of the PET filament, as well as exploring surface modification techniques,
such as plasma treatment or coatings, to enhance the filament's adhesion and printability characteristics,
are significant technical hurdles that must be addressed.

7.2 Challenges:

a) Non-existence of project components in Yemen:

Sourcing the required components for our PET filament extruder project is difficult within Yemen due
to limited availability. We should explore alternative suppliers in the region to mitigate the logistics and
cost challenges.

b) Lack of sources:
Information and resources related to our project are scarce, hindering our progress. We should leverage
online communities, experts, and collaborative opportunities to access the necessary guidance and
support.

c) Lack of workshops for fabrication:

The university's workshop is always closed, preventing us from utilizing the required equipment and
tools for fabrication. We need to engage with the administration to improve workshop access or explore
alternative fabrication facilities.

d) High cost:
The project components, outsourced fabrication, and international shipping are expensive. We should
prioritize requirements, explore funding opportunities, and consider a phased approach to manage the
financial challenges.

e) Lack of manuals for the ordered components:

Missing user manuals and technical documentation for the project components make integration and
troubleshooting difficult. We should request the necessary information from suppliers or search for
similar resources online.

f) Precision Cutting of 1 mm Thick Tapes:

One of the key challenges in this project is the difficulty in building a precision cutter to obtain plastic
tapes with a consistent thickness of 1 mm. The thinness of the desired tapes, combined with the potential
variability in the extruded filament diameter, makes it challenging to design and fabricate a reliable
cutting mechanism that can consistently produce the target 1 mm thickness. Achieving the precise
control and tolerances required to cut the extruded filament into uniform 1 mm thick tapes is a significant
engineering hurdle that must be overcome.

g) Smooth and Uncontaminated Plastic Bottles:

Another challenge is the need to ensure that the plastic bottles used as the raw material are smooth and
free from contaminants before being heated and extruded. The heating process required for PET
extrusion can potentially amplify any surface imperfections or contaminants present in the original
plastic bottles, leading to issues with the final extruded filament. Scratches, dents, or any other physical
irregularities on the surface of the plastic bottles can cause inconsistencies in the extruded filament,
while chemical contaminants can affect the material properties and appearance of the final product.
Careful cleaning, inspection, and preparation of the plastic bottles is essential to overcome this challenge
and produce high-quality, uncontaminated PET filament that can be easily cut into the desired 1 mm
thick tapes.

8. CONCLUSION:

The lack of access to adequate fabrication facilities on our university campus presents a significant
challenge that we must overcome in order to successfully develop our PET filament extruder project.
Without the ability to perform necessary fabrication tasks such as machining, grinding, and cutting
within our own university workshops, we have been forced to seek external service providers. This
introduces additional logistical complexities and financial implications, particularly due to the
challenges of international shipping.

The fact that our university's workshop is always closed further exacerbates this problem, as we are
unable to utilize the resources and tools that should be readily available to us as students. This lack of
access to the necessary equipment and facilities on our own campus is a major obstacle hindering the
progress of our project.

To address this critical challenge, we need to take a proactive approach. We should engage directly with
the university administration and the workshop staff to understand the reasons behind the limited
availability and restricted access to these facilities. Armed with this information, we can then advocate
for increased operating hours and dedicated access for our project-related fabrication needs.

Proposing a structured schedule or access plan that would allow us to utilize the workshop for our
specific project requirements could be an effective strategy. In our discussions, we should emphasize the
educational and research value that providing us this access would bring to the university. Highlighting
how it would enhance our learning experience and contribute to the institution's reputation as an
innovative hub could help strengthen our case.

If obtaining increased access to the university's own workshop proves challenging, we should also
explore alternative options. This may involve gaining access to other university or local maker spaces,
either within our region or through collaborative arrangements with partner institutions. These external
facilities may have the necessary equipment and tools to support our hands-on fabrication requirements.

Resolving this lack of access to adequate fabrication facilities is a crucial step towards the successful
completion of our PET filament extruder project. By persistently engaging with the university
administration, advocating for increased workshop availability, and exploring alternative options, we
can overcome this significant obstacle and make meaningful progress in our endeavor.

9. REFERENCES:
[1] Zamani, A., Edvardsson, S., & Larsson, P. O. (2019). Optimizing parameters for a 3D printer
filament extruder using PET plastic waste. Polymer Engineering & Science, 59(7), 1389-1397.
https://onlinelibrary.wiley.com/doi/abs/10.1002/pen.25117

[2] Gwon, J. G., Lee, S. Y., Doh, G. H., & Kim, J. H. (2010). Compatibility of thermoplastic polymer
composites containing recycled newspaper fiber. Journal of Composite Materials, 44(24), 2806-2815.
https://journals.sagepub.com/doi/abs/10.1177/0021998310374677

[3] Tao, Y., Wang, H., Li, Z., Li, P., & Shi, S. Q. (2017). Development and application of wood
plastic composite materials in the manufacturing industry. International Journal of Polymer Science,
2017.
https://www.hindawi.com/journals/ijps/2017/5518930/

[4] Eshkoor, R. A., Tamin, M. N., Ishak, M. R., & Azhari, C. H. (2017). Mechanical properties of
wastetyre-reinforced polymer composites: A review. Journal of Thermoplastic Composite Materials,
30(2), 143-165.
https://journals.sagepub.com/doi/abs/10.1177/0892705715601038
http://electronoobs.com/eng_arduino_tut24_sch3.php

10. APPENDICES:

Appendix (1) Arduino Code

#include

const int stepsPerRevolution = 200;

Stepper myStepper(stepsPerRevolution, 8, 9, 10, 11);

void setup() {
 myStepper.setSpeed(50);

Serial.begin(9600);

void loop() {

// step one for one direction:

Serial.println("clockwise");

myStepper.step(stepsPerRevolution);