RepRap

This article explores a new open-source method for developing and manufacturing high-quality scientific equipment suitable for use in virtually any laboratory. A syringe pump was designed using freely available open-source computer aided design (CAD) software and manufactured using an open-source RepRap 3-D printer and readily available parts. The design, bill of materials and assembly instructions are globally available to anyone wishing to use them. Details are provided covering the use of the CAD software and the RepRap 3-D printer. The use of an open-source Rasberry Pi computer as a wireless control device is also illustrated. Performance of the syringe pump was assessed and the methods used for assessment are detailed. The cost of the entire system, including the controller and web-based control interface, is on the order of 5% or less than one would expect to pay for a commercial syringe pump having similar performance. The design should suit the needs of a given research activity requiring a syringe pump including carefully controlled dosing of reagents, pharmaceuticals, and delivery of viscous 3-D printer media among other applications.

Standard fused filament fabrication (FFF)-based 3-D printers fabricate parts from thermopolymers, such as polylactic acid (PLA). A new range of metal based PLA composites are available providing a novel range of potential engineering materials for such 3-D printers. Currently, limited material data, specifically thermal property characterization is available on these composites. As a result, the application of these materials into functional engineered systems is not possible. This study aims to fill the knowledge gap by quantifying the thermal properties of copperFill, bronzeFill, magnetic iron PLA, and stainless steel PLA composites and provide insight into the technical considerations of FFF composite 3-D printing. Specifically, in this study the correlation of the composite microstructure and printing parameters are explored and the results of thermal conductivity analysis as a function of printed matrix properties are provided. Considering the relative deviation from the filament raw bulk analysis, the results show the printing operation significantly impacts the resultant component density. Experimentally collected thermal conductivity values, however, do not correlate to the theoretical models in the literature and more rigorous quantitative exercises are required to determine true percent porosity to accurately model the effect of air pore volume fraction on thermal conductivity. Despite this limitation, the thermal conductivity values provided can be used to engineer thermal conductivity into 3-D printed parts with these PLA-based composites. Finally, several high-value applications of such 3-D printed materials that look metallic, but have low thermal conductivity are reviewed.

"Technical progress in the open-source self replicating rapid prototyper (RepRap) community has enabled a distributed form of additive manufacturing to expand rapidly using polymer-based materials. However, the lack of an open-source metal alternative and the high capital costs and slow throughput of proprietary commercialized metal 3-D printers has severely restricted their deployment. The applications of commercialized metal 3-D printers are limited to only rapid prototyping and expensive finished products. This severely restricts the access of the technology for small and medium enterprises, the developing world and for use in laboratories. This paper reports on the development of a <$2000 open-source metal 3-D printer. The metal 3-D printer is controlled with an open-source micro-controller and is a combination of a low-cost commercial gas-metal arc welder and a derivative of the Rostock, a deltabot RepRap. The bill of materials, electrical and mechanical design schematics, and basic construction and operating procedures are provided. A preliminary technical analysis of the properties of the 3-D printer and the resultant steel products are performed. The results of printing customized functional metal parts are discussed and conclusions are drawn about the potential for the technology and the future work necessary for the mass distribution of this
technology."

In order to assist researchers explore the full potential of distributed recycling of post-consumer polymer waste, this article describes a recyclebot, which is a waste plastic extruder capable of making commercial quality 3-D printing filament. The device design takes advantage of both the open source hardware methodology and the paradigm developed by the open source self-replicating rapid prototyper (RepRap) 3-D printer community. Specifically, this paper describes the design, fabrication and operation of a RepRapable Recyclebot, which refers to the Recyclebot's ability to provide the filament needed to largely replicate the parts for the Recyclebot on any type of RepRap 3-D printer. The device costs less than $700 in mate rials and can be fabricated in about 24 h. Filament is produced at 0.4 kg/h using 0.24 kWh/kg with a diameter ±4.6%. Thus, filament can be manufactured from commercial pellets for <22% of commercial filament costs. In addition, it can fabricate recycled waste plastic into filament for 2.5 cents/kg, which is <1000X commercial filament costs. The system can fabricate filament from polymers with extrusion temperatures <250 °C and is thus capable of manufacturing custom filament over a wide range of thermopolymers and composites for material science studies of new materials and recyclability studies, as well as research on novel applications of fused filament based 3-D printing.

Although the environmental benefits of recycling plastics are well established and most geographic locations within the U.S. offer some plastic recycling, recycling rates are often low. Low recycling rates are often observed in conventional centralized recycling plants due to the challenge of collection and transportation for high-volume low-weight polymers. The recycling rates decline further when low population density, rural and relatively isolated communities are investigated because of the distance to recycling centers makes recycling difficult and both economically and energetically inefficient. The recent development of a class of open source hardware tools (e.g. RecycleBots) able to convert post-consumer plastic waste to polymer filament for 3-D printing offer a means to increase recycling rates by enabling distributed recycling. In addition, to reducing the amount of plastic disposed of in landfills, distributed recycling may also provide low-income families a means to supp...

Historically, open source agriculture (OSA) was based on grassroots technology generally manufactured by hand tools or with manual machining. The rise of distributed digital manufacturing provides an opportunity for much more rapid lateral scaling of open source appropriate technologies for agriculture. However, the most mature distributed manufacturing area is plastic, which has limited use for many OSA applications. To overcome this limitation with design, this study reports on of a completely 3D-printable planetary roller screw linear actuator. The device is designed as a parametric script-based computer aided design (CAD) package to allow for the easy adaption for a number of applications such as food processing at different scales. The planetary roller screw is fabricated in dishwasher-safe polyethylene terephthalate glycol (PETG) on an open source machine and tested using an open source testing platform to determine if it could maintain a constant load without slipping and the maximum force. Then, this output is compared to a direct screw press using the same materials. The results found that the maximum force is more than doubled for the roller screw actuator using the same materials, making them adequate for some food processing techniques. Future work is outlined to improve the performance and ease of assembly.

The combination of open-source software and hardware provide technically feasible methods to create low-cost, highly-customized scientific research equipment. Open-source 3-D printers have proven useful for fabricating scientific tools. Here the capabilities of an open-source 3-D printer are expanded to become a highly-flexible scientific platform. An automated low-cost 3-D motion control platform is presented having the capacity to perform scientific applications including: i) 3-D printing of scientific hardware, ii) laboratory auto-stirring, measuring and probing, iii) automated fluid handling and iv) shaking and mixing. The open-source 3-D platform not only facilities routine research while radically reducing the cost, but it also inspires the creation of a diverse array of custom instruments that can be shared and replicated digitally throughout the world to drive down the cost of research and education further.

In the Upper Peninsula of Michigan, over 500 million tons of copper rich rock were removed from mines and treated in chemical baths to extract copper. Toxic substances have been seeping into the watersheds from the resultant waste stamp sands. Recent work on developing a circular economy using recycled plastic for distributed manufacturing technologies has proven promising, and this study investigates the potential to use this approach to form stamp sand and acrylonitrile styrene acrylate (ASA) composites. Specifically, this study found the maximum amount of stamp sand that was able to be added to waste ASA by mass with a single auger recyclebot system for compounding was below 40%. The mechanical properties of the composite were evaluated up to 40%, and the addition of stamp sand reduced the material's ultimate tensile strength by about half compared to the strength of raw recycled ASA, regardless of the percent stamp sand in the composite. However, this strength reduction plateaus and the tensile strength of the ASA and stamp sand composites can be compared favorably with acrylonitrile butadiene styrene (ABS) at any level. This makes waste ASA-stamp sand composites potential replacements for outdoor applications of ABS as well as some current ASA applications. These results are promising and call for future work to evaluate the technical, economic and environmental potential for waste ASA-stamp sand composites.

Although additive layer manufacturing is well established for rapid prototyping the low throughput and historic costs have prevented mass-scale adoption. The recent development of the RepRap, an open source self-replicating rapid prototyper, has made low-cost 3-D printers readily available to the public at reasonable prices (<$1,000). The RepRap (Prusa Mendell variant) currently prints 3-D objects in a 200x200x140 square millimeters build envelope from acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA). ABS and PLA are both thermoplastics that can be injection-molded, each with their own benefits, as ABS is rigid and durable, while PLA is plant-based and can be recycled and composted. The melting temperature of ABS and PLA enable use in low-cost 3-D printers, as these temperature are low enough to use in melt extrusion in the home, while high enough for prints to retain their shape at average use temperatures. Using 3-D printers to manufacture provides the ability to both change the fill composition by printing voids and fabricate shapes that are impossible to make using tradition methods like injection molding. This allows more complicated shapes to be created while using less material, which could reduce environmental impact.

As the open source 3-D printers continue to evolve and improve in both cost and performance, the potential for economically-viable distributed manufacturing of products increases. Thus, products and components could be customized and printed on-site by individual consumers as needed, reversing the historical trend towards centrally mass-manufactured and shipped products. Distributed manufacturing reduces embodied transportation energy from the distribution of conventional centralized manufacturing, but questions remain concerning the potential for increases in the overall embodied energy of the manufacturing due to reduction in scale. In order to quantify the environmental impact of distributed manufacturing using 3-D printers, a life cycle analysis was performed on a plastic juicer. The energy consumed and emissions produced from conventional large-scale production overseas are compared to experimental measurements on a RepRap producing identical products with ABS and PLA. The results of this LCA are discussed in relation to the environmental impact of distributed manufacturing with 3-D printers and polymer selection for 3-D printing to reduce this impact. The results of this study show that distributed manufacturing uses less energy than conventional manufacturing due to the RepRap's unique ability to reduce fill composition. Distributed manufacturing also has less emissions than conventional manufacturing when using PLA and when using ABS with solar photovoltaic power. The results of this study indicate that open-source additive layer distributed manufacturing is both technically viable and beneficial from an ecological perspective.

The recent development of open-source 3-D printers makes scaling of distributed additive-based manufacturing of high-value objects technically feasible. These self-replicating rapid prototypers (RepRaps) can manufacture approximately half of their own parts from sequential fused deposition of polymer feedstocks. RepRaps have been proposed and demonstrated to be useful for conventional prototyping and engineering, customizing scientific equipment, and appropriate technology-related manufacturing for sustainable development. However, in order for this technology to proliferate like 2-D electronic printers have, it must be economically viable for a typical household. This study reports on the life-cycle economic analysis (LCEA) of RepRap technology for an average U.S. household. A new low-cost RepRap is described and the costs of materials and time to construct it are quantified. The economic costs of a selection of twenty open-source printable designs (representing less than 0.04% of those available), are typical of products that a household might purchase, are quantified for print time, energy, and filament consumption and compared to low and high Internet market prices for similar products without shipping costs. The results show that even making the extremely conservative assumption that the household would only use the printer to make the selected twenty products a year the avoided purchase cost savings would range from about $300 to $2000/year. Assuming the 25 hours of necessary printing for the selected products is evenly distributed throughout the year these savings provide a simple payback time for the RepRap in 4 months to 2 years and provide an ROI between >200% and >40%. As both upgrades and the components that are most likely to wear out in the RepRap can be printed and thus the lifetime of the distributing manufacturing can be substantially increased the unavoidable conclusion from this study is that the RepRap is an economically attractive investment for the average U.S. household already. It appears clear that as RepRaps improve in reliability, continue to decline in cost and both the number and assumed utility of open-source designs continues growing exponentially, open-source 3-D printers will become a mass-market mechatronic device.

This study explores the potential to reach a circular economy for post-consumer Recycled Polyethylene Terephthalate (rPET) packaging and bottles by using it as a Distributed Recycling for Additive Manufacturing (DRAM) feedstock. Specifically, for the first time, rPET water bottle flake is processed using only an open source toolchain with Fused Particle Fabrication (FPF) or Fused Granular Fabrication (FGF) processing rather than first converting it to filament. In this study, first the impact of granulation, sifting, and heating (and their sequential combination) is quantified on the shape and size distribution of the rPET flakes. Then 3D printing tests were performed on the rPET flake with two different feed systems: an external feeder and feed tube augmented with a motorized auger screw, and an extruder-mounted hopper that enables direct 3D printing. Two Gigabot X machines were used, each with the different feed systems, and one without and the latter with extended part cooling. 3D print settings were optimized based on thermal characterization, and both systems were shown to 3D print rPET directly from shredded water bottles. Mechanical testing showed the importance of isolating rPET from moisture and that geometry was important for uniform extrusion. The mechanical strength of 3D-printed parts with FPF and inconsistent flow is lower than optimized fused filament, but adequate for a wide range of applications. Future work is needed to improve consistency and enable water bottles to be used as a widespread DRAM feedstock.

"Open-Source Lab: How to Build Your Own Hardware and Reduce Scientific Research Costs details the development of the free and open-source hardware revolution. The combination of open-source 3D printing and open-source microcontrollers running on free software enables scientists, engineers, and lab personnel in every discipline to develop powerful research tools at unprecedented low costs.

After reading Open-Source Lab, you will be able to:

    >Lower equipment costs by making your own hardware
    >Build open-source hardware for scientific research
    >Actively participate in a community in which scientific results are more easily replicated and cited

The recent development of the RepRap, an open-source self-replicating rapid prototyper, has made 3-D polymer-based printers readily available to the public at low costs (<$500). The resultant uptake of 3-D printing technology enables for the first time mass-scale distributed digital manufacturing. RepRap variants currently fabricate objects primarily from acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA), which have melting temperatures low enough to use in melt extrusion outside of a dedicated facility, while high enough for prints to retain their shape at average use temperatures. In order for RepRap printed parts to be useful for engineering applications the mechanical properties of printed parts must be known. This study quantifies the basic tensile strength and elastic modulus of printed components using realistic environmental conditions for standard users of a selection of open-source 3-D printers. The results find average tensile strengths of 28.5 MPa for ABS and 56.6 MPa for PLA with average elastic moduli of 1807 MPa for ABS and 3368 MPa for PLA. It is clear from these results that parts printed from tuned, low-cost, open-source RepRap 3-D printers can be considered as mechanically functional in tensile applications as those from commercial vendors.

The open source introduction of fused filament fabrication (FFF) enables distributed manufacturing of consumer products. However, with a wide range of low-cost FFF 3-D printers and settings possible, there is a lack of information on the variability in printed mechanical properties. This paper utilizes a large pool of 47 user-assembled 3-D printers to quantify the mechanical property variations of ultimate tensile strength (UTS) and yield strength of FFF printed components using ASTM D638-14 horizontally-oriented Type I and IV geometries for poly lactic acid (PLA). The results indicate that utilizing Type IV tensile test piece geometry may overestimate the UTS relative to the Type I. Furthermore, anisotropic mechanical property variances were quantified for Type IV specimens (vertical and horizontal orientations). Vertical tensile specimens had an ultimate tensile strength 47.9% less than horizontal. Finally, the abundant supply of PLA 3-D prints suggest open-source printers assembled by individual operators can produce quality plastic components although the mechanical performance of the given part can vary dramatically based on the operator selection of printing parameters that provide a visually acceptable part.

This study analyzes a low-cost reliable real-time optimal monitoring platform for fused filament fabrication-based open source 3-D printing. An algorithm for reconstructing 3-D images from overlapping 2-D intensity measurements with relaxed camera positioning requirements is compared with a single camera solution for single side 3-D printing monitoring. The algorithms are tested for different 3-D object geometry and filament colors. The results showed that both of the algorithms with a single and double camera system were effective at detecting a clogged nozzle, incomplete project, or loss of filament for a wide range of 3-D object geometries and filament colors. The combined approach was the most effective and achieves 100 percent detection rate for failures. The combined method analyzed here has a better detection rate and a lower cost compared to previous methods. In addition, this method is generalizable to a wide range of 3-D printer geometries, which enables further deployment of desktop 3-D printing as wasted print time and filament are reduced, thereby improving the economic advantages of distributed manufacturing.

RepRaps (self Replicating Rapid prototypers), which 3-D print objects using fused filament fabrication (FFF), have evolved rapidly since their open source introduction. These 3-D printers have primarily been limited to desktop sizes of volumes of ~8000 cm 3 , which has limited the attention of the scientific community to investigating deformation of common thermoplastics such as polylactic acid (PLA) used in FFF printing. The only existing physically relevant deformation model was expanded here to use a physics-based temperature gradient instead of a step function. This was necessary to generalize the model to 3-D printing in a room temperature environment without a heated chamber. The thermal equation was calibrated using thermal measurements and validated by measuring curvatures in printed objects. The results confirm that this is a valid model for predicting warpage of thin vertical walls of PLA. Additionally, the effect of annealing was examined. It was found that at a temperature of 50°C, no shrinkage or crystallization takes place, but at 90°C the PLA rapidly crystallizes to around 20% crystallinity. This indicates that heated bed temperatures should be maintained at 50 o C or lower to avoid print failure (premature substrate release) with PLA. At 90°C, the annealing is accompanied by a 5% size decrease in both horizontal dimensions, but an 8% increase in the vertical dimension. Thus, the volume decreased by only 3%. This observation may lead to potential methods of improving slicing of printing large PLA objects with FFF.

Arduino open-source microcontrollers are well known in sensor applications for scientific equipment and for controlling RepRap 3D printers. Recently low-cost open-source gas metal arc weld (GMAW) RepRap 3D printers have been developed. The entry-level welders used have minimal controls and therefore lack any real-time measurement of welder voltage or current. The preliminary work on process optimization of GMAW 3D printers requires a low-cost sensor and data logger system to measure welder current and voltage. This paper reports on the development of a low-cost open-source power measurement sensor system based on Arduino architecture. The sensor system was designed, built, and tested with two entry-level MIG welders. The full bill of materials and open source designs are provided. Voltage and current were measured while making stepwise adjustments to the manual voltage setting on the welder. Three conditions were tested while welding with steel and aluminum wire on steel substrates to assess the role of electrode material, shield gas, and welding velocity. The results showed that the open source sensor circuit performed as designed and could be constructed for <$100 in components representing a significant potential value through lateral scaling and replication in the 3D printing community.

To overcome the challenge of upcycling plastic waste into 3D printing filament in the distributed recycling and additive manufacturing systems, this study designs, builds, tests and validates an open source filament diameter sensor for recycling and winding machines. The modular system for multi-axis optical control of the diameter of the recycled 3D-printer filament makes it possible to scan part of the surface of the 1 Corresponding author

3-D printing shows great potential in laboratories for making customized labware and reaction vessels. In addition, affordable fused filament fabrication (FFF)-based 3-D printing has successfully produced high-quality and affordable scientific equipment, focusing on tools without strict chemical compatibility limitations. As the additives and colorants used in 3-D printing filaments are proprietary, their compatibility with common chemicals is unknown, which has prevented their widespread use in laboratory chemical processing. In this study, the compatibility of ten widely available FFF plastics with solvents, acids, bases and solutions used in the wet processing of semiconductor materials is explored. The results provide data on materials unavailable in the literature and the chemical properties of 3-D printable plastics that were, are in line with literature. Overall, many 3-D printable plastics are compatible with concentrated solutions. Polypropylene emerged as a promising 3-D printable material for semiconductor processing due to its tolerance of strongly oxidizing acids, such as nitric and sulfuric acids. In addition, 3-D printed custom tools were demonstrated for a range of wet processing applications. The results show that 3-D printed plastics are potential materials for bespoke chemically resistant labware at less than 10% of the cost of such purchased tools. However, further studies are required to ascertain if such materials are fully compatible with clean room processing.

The open-source release of self-replicating rapid prototypers (RepRaps) has created a rich opportunity for low-cost distributed digital fabrication of complex 3-D objects such as scientific equipment. For example, 3-D printable reactionware devices offer the opportunity to combine open hardware microfluidic handling with lab-on-a-chip reactionware to radically reduce costs and increase the number and complexity of microfluidic applications. To further drive down the cost while improving the performance of lab-on-a-chip paper-based microfluidic prototyping, this study reports on the development of a RepRap upgrade capable of converting a Prusa Mendel RepRap into a wax 3-D printer for paper-based microfluidic applications. An open-source hardware approach is used to demonstrate a 3-D printable upgrade for the 3-D printer, which combines a heated syringe pump with the RepRap/Arduino 3-D control. The bill of materials, designs, basic assembly, and use instructions are provided, along with a completely free and open-source software tool chain. The open-source hardware device described here accelerates the potential of the nascent field of electrochemical detection combined with paper-based microfluidics by dropping the marginal cost of prototyping to nearly zero while accelerating the turnover between paper-based microfluidic designs.

With the maturation of digital manufacturing technologies like 3-D printing, a new paradigm is emerging of distributed manufacturing in both scientific equipment and consumer goods. Hardware released under free licenses is known as free and open source hardware (FOSH). The availability of these FOSH designs has a large value to those with access to digital manufacturing methods and particularly for scientists with needs for highly-customized low-volume production products. It is challenging to use traditional funding models to support the necessary investment of resources in FOSH development because of the difficulty in quantifying the value of the result. In order to overcome that challenge and harvest the current opportunity in both low-cost scientific equipment and consumer products, this article evaluates the following methods to quantify the value of FOSH design including: 1) downloaded substitution valuation; 2) avoided reproduction valuation and 3) market savings valuation along with additional benefits related to market expansion, scientific innovation acceleration, educational enhancement and medical care improvement. The strengths and weaknesses of these methods are analyzed and the results show that the methods are relatively straight-forward to institute, based on reliable freely-available data, and that they minimize assumptions. A case study of a syringe pump with numerous scientific and medical applications is presented. The results found millions of dollars of economic value from a relatively simple scientific device being released under open-licenses representing orders of magnitude increase in value from conventional proprietary development. The inescapable conclusion of this study is that FOSH development should be funded by organizations interested in maximizing return on public investments particularly in technologies associated with science, medicine and education.

Open source 3d printing technology opens the door for small and medium-sized businesses, as well as freelancers to take on industry challenges so far reserved for large companies. Production on demand is economically viable thanks to this system, and in the furniture industry, it greatly reduces the environmental impact of production. The importance of adding personal value to production adds to the possibility of reusing plastics such as PET, causing a great global pollution, thus providing an update to a new responsible industry.

Slot die coating is growing in popularity because it is a low operational cost and easily scaled processing technique for depositing thin and uniform films rapidly, while minimizing material waste. The complex inner geometry of conventional slot dies require expensive machining that limits accessibility and experimentation. In order to overcome these issues this study follows an open hardware approach, which uses an open source 3-D printer to both fabricate the slot die and then to functionalize a 3-D slot die printing system. Polymer materials are tested and selected for compatibility with common solvents and used to fabricate a custom slot die head. This slot die is then integrated into a 3-D printer augmented with a syringe pump to form an additive manufacturing platform for thin film semiconductor devices. The full design of the slot die system is disclosed here using an open source license including software and operational protocols. This study demonstrates that functional lab-grade slot dies may be 3-D printed using low-cost open source hardware methods. A case study using NiO2 found an RMS value 0.486 nm, thickness of 17 to 49nm, and a maximum optical transmission of 99.1%, which shows this additive manufacturing approach to slot die depositions as well of fabrication is capable of producing viable layers of advanced electronic materials. Using this method, a cost savings of over 17,000% was obtained when compared to commercial slot die systems for laboratories.

Most experimental research projects are executed with a combination of purchased hardware equipment, which may be modified in the laboratory and custom single-built equipment fabricated inhouse. However, the computer software that helps design and execute experiments and analyze data has an additional source: It can also be free and open-source software (FOSS). FOSS has the advantage that the code is openly available for modification and is also often free of charge. In the past, customizing software has been much easier than custom-building equipment, which often can be quite costly because fabrication requires the skills of machinists, glassblowers, technicians, or outside suppliers. However, the open-source paradigm is now enabling creation of open-source scientific hardware by combining 3D printing with open-source microcontrollers running on FOSS. These developments are illustrated below by several examples of equipment fabrication that can better meet particular specifications at substantially lower overall costs.

As facilitators of 3D printer workshops, the authors developed a survey to gage how the printers are actually being used and whether they support the Next Generation Science Standards (NGSS) requirements, especially in regard to engineering design. The survey response rate was 52% of 68 total participants with the majority conveying that 3D printers do facilitate student understanding of the engineering design process and that the workshops empowered them and their students to tackle projects previously perceived as beyond their skill level. Insufficient preparation for troubleshooting hardware and software issues was listed as the greatest barrier to fully realizing the technology’s potential in the classroom. Also highlighted was a lack of resources for development of meaningful lesson plans using this nascent technology.

Purpose – A low-cost, open source, self-replicating rapid prototyper (RepRap) has been developed, which greatly expands the potential user base of rapid prototypers. The operating cost of the RepRap can be further reduced using waste polymers as feedstock. Centralized recycling of polymers is often uneconomic and energy intensive due to transportation embodied energy. The purpose of this paper is to provide a proof of concept for high-value recycling of waste polymers at distributed creation sites.

Design/methodology/approach – Previous designs of waste plastic extruders (also known as RecycleBots) were evaluated using a weighted evaluation matrix. An updated design was completed and the description and analysis of the design is presented including component summary, testing procedures, a basic life cycle analysis and extrusion results. The filament was tested for consistency of density and diameter while quantifying electricity consumption.

Findings – Filament was successfully extruded at an average rate of 90?mm/min and used to print parts. The filament averaged 2.805?mm diameter with 87 per cent of samples between 2.540?mm and 3.081?mm. The average mass was 0.564?g/100?mm length. Energy use was 0.06?kWh/m.

Practical implications – The success of the RecycleBot further reduces RepRap operating costs, which enables distributed in-home, value added, plastic recycling. This has implications for municipal waste management programs, as in-home recycling could reduce cost and greenhouse gas emissions associated with waste collection and transportation, as well as the environmental impact of manufacturing custom plastic parts.

Originality/value – This paper reports on the first technical evaluation of a feedstock filament for the RepRap from waste plastic material made in a distributed recycling device.

The growth of desktop 3-D printers is driving an interest in recycled 3-D printer filament to reduce costs of distributed production. Life cycle analysis studies were performed on the recycling of high density polyethylene into filament suitable for additive layer manufacturing with 3-D printers. The conventional centralized recycling system for high population density and low population density rural locations was compared to the proposed in home, distributed recycling system. This system would involve shredding and then producing filament with an open-source plastic extruder from post-consumer plastics and then printing the extruded filament into usable, value-added parts and products with 3-D printers such as the open-source self replicating rapid prototyper, or RepRap. The embodied energy and carbon dioxide emissions were calculated for high density polyethylene recycling using SimaPro 7.2 and the database EcoInvent v2.0. The results showed that distributed recycling uses less embodied energy than the best-case scenario used for centralized recycling. For centralized recycling in a low-density population case study involving substantial embodied energy use for transportation and collection these savings for distributed recycling were found to extend to over 80%. If the distributed process is applied to the U.S. high density polyethylene currently recycled, more than 100 million MJ of energy could be conserved per annum along with the concomitant significant reductions in greenhouse gas emissions. It is concluded that with the open-source 3-D printing network expanding rapidly the potential for widespread adoption of in-home recycling of post-consumer plastic represents a novel path to a future of distributed manufacturing appropriate for both the developed and developing world with lower environmental impacts than the current system.

As additive manufacturing rapidly expands the number of materials including waste plastics and composites, there is an urgent need to reduce the experimental time needed to identify optimized printing parameters for novel materials. Computational intelligence (CI) in general and particle swarm optimization (PSO) algorithms in particular have been shown to accelerate finding optimal printing parameters. Unfortunately, the implementation of CI has been prohibitively complex for noncomputer scientists. To overcome these limitations, this article develops, tests, and validates PSO Experimenter, an easy-to-use open-source platform based around the PSO algorithm and applies it to optimizing recycled materials. Specifically, PSO Experimenter is used to find optimal printing parameters for a relatively unexplored potential distributed recycling and additive manufacturing (DRAM) material that is widely available: low-density polyethylene (LDPE). LDPE has been used to make filament, but in this study for the first time it was used in the open source fused particle fabrication/fused granular fabrication system. PSO Experimenter successfully identified functional printing parameters for this challenging-to-print waste plastic. The results indicate that PSO Experimenter can provide 97% reduction in research time for 3D printing parameter optimization. It is concluded that the PSO Experimenter is a user-friendly and effective free software for finding ideal parameters for the burgeoning challenge of DRAM as well as a wide range of other fields and processes.

The purpose of this paper is to provide a technical and economic evaluation of the value of the RepRap as an entry-level 3-D printer in the developing world and provide a cost effective solar photovoltaic (PV) racking solution to better serve the developing world and aid in the acceleration of their economic and socioeconomic growth. A customizable open-source PV racking concept is designed, prototyped for three types of modules, constructed into systems, and outdoor tested under extreme conditions for one year. An economic analysis is provided along with a technical evaluation of the system, which found the proposed racking system can be successfully printed with RepRap 3-D printers and saves between 85% and 92% from commercially available alternatives depending on the plastic used for printing. In addition, the plastic parts proved able to withstand some of the harshest outdoor conditions and due to the free and open-source nature of the designs, it allows the system to be adapted to custom applications in any region in the world more easily than any commercial alternatives. The results indicate that the 3-D printable X-wire solar photovoltiac racking system has the potential to aid in the acceleration of solar deployment in the developing world by providing a low cost PV racking solution.

The availability of free and open source hardware designs that can be replicated with low-cost 3-D printers provide large values to scientists that need highly-customized low-volume production scientific equipment. Digital manufacturing technologies have only recently become widespread and the return on investment (ROI) was not clear, so funding for open hardware development was historically sparse. This paper clarifies a method for determining an ROI for FOSH scientific hardware development. By using open source hardware design that can be manufactured digitally the relatively minor development costs result in enormous ROIs for the scientific community. A case study is presented of an syringe pump released under open-licenses, which results in ROIs for funders ranging from 100s to 1,000s of percent after only a few months. It is clear that policies encouraging free and open source scientific hardware development should be made by organizations interested in maximizing return on public investments for science.

The rapid technical evolution of additive manufacturing (AM) enables a new path to a circular economy using distributed recycling and production. This concept of Distributed Recycling via Additive Manufacturing (DRAM) is related to the use of recycled materials by means of mechanical recycling process in the 3D printing process chain. This paper aims to examine the current advances on thermoplastic recycling processes via additive manufacturing technologies. After proposing a closed recycling global chain for DRAM, a systematic literature review including 92 papers from 2009 to 2019 was performed using the scopus, web of science and springer databases. This work examines main topics from six stages (recovery, preparation, compounding, feedstock, printing, quality) of the proposed DRAM chain. The results suggested that few works have been done for the recovery and preparation stages, while a great progress has already been done for the other stages in order to validate the technical feasibility, environmental impact, and economic viability. Potential research paths in the pre-treatment of recycled material at local level and printing chain phases were identified in order to connect the development of DRAM with the circular economy ambition at micro, meso and macro level. The development of each stage proposed using the open source approach is a relevant path to scale DRAM to reach the full technical potential as a centerpiece of the circular economy.

As low-cost desktop 3D printing is now dominated by free and open source self-replicating rapid prototype (RepRap) derivatives, there is an intense interest in extending the scope of potential applications to manufacturing. This study describes a manufacturing technology that enables a constrained set of polymer-metal composite components. This paper provides (1) free and open source hardware and (2) software for printing systems that achieves metal wire embedment into a polymer matrix 3D-printed part via a novel weaving and wrapping method using (3) OpenSCAD and parametric coding for customized g-code commands. Composite parts are evaluated from the technical viability of manufacturing and quality. The results show that utilizing a multi-polymer head system for multi-component manufacturing reduces manufacturing time and reduces the embodied energy of manufacturing. Finally, it is concluded that an open source software and hardware tool chain can provide low-cost industrial manufacturing of complex metal-polymer composite-based products.

A remaining challenge to enable free and open source open hardware (FOSH) to catch up with now industry-dominant free and open source software (FOSS) is identifying appropriate business models. In this article a new FOSH business model is discussed, specialty components for fabricators, using a case study of an open source screw manufacturer business. The case study explores the economics of building a system meant to fabricate a specialty component for other businesses and prosumers working in the distributed recycling and additive manufacturing (DRAM) space. The component payback time is calculated under various scenarios, the sales necessary to provide an enticing income for a small business is quantified and the point at which business expansions is necessary is determined. The results indicate to serve the burgeoning DRAM market more than 1000 small businesses could follow a Do It Together (DIT) approach of sharing FOSH designs while manufacturing and profiting locally.

The relatively sudden widespread attention of the concept of distributed manufacturing with 3-D printing is largely due to the development of open-source 3-D printers. One that could make its own parts, radically increased innovation rates and shrunk the costs of 3-D printers. Proprietary
3-D printers prior had cost hundreds of thousands of dollars and the least expensive sold for $20,000. Today an open source 3-D printer costs $160 and dozens of 3-D printers from different companies cost under $200. Several studies showed consumers could easily profit by 3-D printing their own products (even if the printers cost more than $1000). The number of
open source designs people can make profitably for themselves is growing exponentially. This short chapter discusses on approach to protecting this freedom to fabricate.

With the aggressive cost reductions for 3-D printing made available by the open-source self-replicating rapid prototypers (RepRaps) the economic advantage of custom distributed manufacturing has become substantial. In addition, the number of free designs is growing exponentially and the development and commercialization of the recyclebot (plastic extruders that fabricate 3-D printing filament from recycled or virgin materials) have greatly improved the material selection available for prosumer 3-D printer operators. These trends indicate that more individuals will manufacturer their own polymer products, however, there is a risk that an even larger fraction of polymer waste will not be recycled because it has not been coded. The current limited resin identification code available in the U.S. similarly restricts closing the loop on less popular polymers, which could hamper the environmental impact benefits of distributed manufacturing. This paper provides a solution for this challenge by (1) developing a recycling code model based off of the resin identification codes developed in China that is capable of expansion as more complex 3-D printing materials are introduced, (2) creating OpenSCAD scripts based on (1) to be used to print resin identification codes into products, (3) demonstrating the use of this functionality in a selection of products and polymer materials, and (4) outlining the software and policy tools necessary to make this application possible for widespread adoption. Overall the results showed that a far larger resin code identification system can be adopted in the U.S. to expand distributed recycling of polymers and manufacturing of plastic-based 3-D printed products.

Distributed digital manufacturing offers a solution to medical supply and technology shortages during pandemics. To prepare for the next pandemic, this study reviews the state-of-the-art for open hardware designs needed in a COVID-19-like pandemic. It evaluates the readiness of the top twenty technologies requested by the Government of India. The results show that the majority of the actual medical products have had some open source development, however, only 15% of the supporting technologies that make the open source device possible are freely available. The results show there is still considerable work needed to provide open source paths for the development of all the medical hardware needed during pandemics. Five core areas of future work are discussed that include:  i) technical development of a wide-range of open source solutions for all medical supplies and devices, ii) policies that protect the productivity of laboratories, makerspaces and fabrication facilities during a pandemic, as well as iii) streamlining the regulatory process, iv) developing Good-Samaritan laws to protect makers and designers of open medical hardware, as well as to compel those with knowledge that will save lives to share it, and v) requiring all citizen-funded research to be released with free and open source licenses.