Low cost 3D printing filament extruder for recycled plastics Low cost filament extruder made from 10 mm ID stainless steel tube, silver soldered inside an ordinary plumber 15 mm copper tube (melt zone) Auger is a 10 mm wood drill bit with the end cut off 5-10 mm in the melt zone. 1 mm hole in a brass endstop at the end of the copper pipe. Aluminium block with a 15 mm hole to fit around the copper pipe. Fixed to the outside of the aluminium two 220 volt 200 degree PTC heaters( I tried 12 volt 230 degrees but the temperature was to high) Insulated with glass fibre cloth. The ptc heaters are available on aliexpress for $1 each) System driven with a car windscreen motor at the low speed (I have a 2 speed motor - salvaged from scrap yard) I use the white plastic that is in the inside of the doors of scrap refrigerators. Cut it up with a circular saw and extrude that to a filament of 1.75 mm I use this filament in my Delta printer on a daily basis. The trick to have a nice filament is to let the filament run over a copper pipe that is suspended in front of the extruder and let natures G force take over. I fix a weight(clothes-peg) at the end of the filament as it comes out of the hole untill it reaches the floor and then move the end of the filament to the outside of a circle approximately 1 meter away.From then on the G force will take over and produce a nice circular movement of the filament to roll it on the floor . The slightest air movement or other external force that you apply to the extruded filament will result in a kink in the filament - no fans required. No fancy electronics involved. Material cost to should be less than $100 This extruder was only tested with the white refrigerator plastic ( I think it is ABS because it will desolve in acetone ) - no ABS pellets or any other plastic tested. https://reprap.org/forum/read.php?70,205005,205005#msg-205005 Wed, 14 Oct 2026 18:55:02 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?70,205005,380625#msg-380625 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,380625#msg-380625
Where can i get recycled pla?
i cant find on ebay


Thanks]]> Anonymous User Plastic Extruder Working Group Wed, 09 Jul 2014 14:11:57 -0400 https://reprap.org/forum/read.php?70,205005,378496#msg-378496 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,378496#msg-378496 PulsedMedia Plastic Extruder Working Group Sat, 05 Jul 2014 09:39:23 -0400 https://reprap.org/forum/read.php?70,205005,360798#msg-360798 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,360798#msg-360798



]]> Dougwar Plastic Extruder Working Group Mon, 26 May 2014 19:32:36 -0400 https://reprap.org/forum/read.php?70,205005,360493#msg-360493 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,360493#msg-360493
Quote
Dougwar
Hi,
I'm trying to do a filament extruder and I get this;


too many bubbles in it, temperature were 190C, do you have any suggestion?
what's the dimension between the nozzle and the auger?
Thanks

I think the temperature may be a bit high hence the bubbles.

Distance between the augers tip and the nozzles inner surface: 80-10 = 70 mm
]]> Xabbax Plastic Extruder Working Group Mon, 26 May 2014 06:22:55 -0400 https://reprap.org/forum/read.php?70,205005,360017#msg-360017 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,360017#msg-360017 1. Black plastic can be difficult to work with due to fillers.
2. Moisture causes bubbles, dry your regrind. What kind of plastic are you extruding?
3. Inconsistent extrusion rate causes thick to thin cross sections. Are you pulling the extrudate? The distance between the screw and nozzle if large could be acting as a spring and pulsing.
4. Screw binding, or friction, if your auger is rubbing the inside of the barrel you could get inconsistent extrudate diameter.
5. Nozzle occlusion, if there is a particle floating in front of the nozzle inside the barrel it will have an effect on the diameter.
6. Drive train, if the gears are jerking you'll get inconsistent extrusion.
7. Melt fracture: when the polymer exits too fast from an extruder, the surface starts to exhibits undulations or irregularities, the distortions can become so severe that they cause the extrudate to break.

You should post a pic of your rig and provide more details.]]> A2 Plastic Extruder Working Group Sun, 25 May 2014 01:23:20 -0400 https://reprap.org/forum/read.php?70,205005,360008#msg-360008 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,360008#msg-360008 I'm trying to do a filament extruder and I get this;


too many bubbles in it, temperature were 190C, do you have any suggestion?
what's the dimension between the nozzle and the auger?
Thanks
]]> Dougwar Plastic Extruder Working Group Sun, 25 May 2014 00:13:17 -0400 https://reprap.org/forum/read.php?70,205005,337764#msg-337764 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,337764#msg-337764
[attachment 30440 IMG_1017_small.jpg]

Runs perfect and the filament comes out smooth and shiny.
Thanks Xabbax for the tips !]]> ianmcmill Plastic Extruder Working Group Thu, 10 Apr 2014 05:17:06 -0400 https://reprap.org/forum/read.php?70,205005,330821#msg-330821 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,330821#msg-330821
Thanks,

Adam]]> admoore Plastic Extruder Working Group Thu, 27 Mar 2014 11:21:25 -0400 https://reprap.org/forum/read.php?70,205005,329089#msg-329089 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,329089#msg-329089
Quote
ianmcmill
Thanks. Getting the laser to work was alot of fun.

Oh I forgot to mention that I am not using pure ABS but a PC/ABS compound. It combines the high temperature rating of PC with the lower one from ABS.
The datasheet says "Processing (melt) temperature = 240-270°C" (Link to the datasheet)

Also when extruding the temperature decreases continuously by circa 0.1-0.2 °C per second and the heater can't keep up. (200 Watt heater). After 30 minutes I stopped the extrusion and the temperature was down to 270°C from 305°C.
I did choose 305°C as a starting temperature because I thought an extra buffer might help the PID/Heater to counteract the temperature decline.

Okay I got it now to the right diameter (1.70mm) without bubbles and raffles. G-force really much helps in adjusting the diameter. The shorter the distance to the floor, the thicker the filament. A fan helps increase the diameter by roughly 0.1mm.

Now to the fun part. Untangle the filament and get on a spool.
There is this filawinder ob the filastruder page. But as with your simplistic low cost but fast extruder do you have another great idea in your backhand ?]]> ianmcmill Plastic Extruder Working Group Sun, 23 Mar 2014 17:57:56 -0400 https://reprap.org/forum/read.php?70,205005,325733#msg-325733 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,325733#msg-325733
Oh I forgot to mention that I am not using pure ABS but a PC/ABS compound. It combines the high temperature rating of PC with the lower one from ABS.
The datasheet says "Processing (melt) temperature = 240-270°C" (Link to the datasheet)

Also when extruding the temperature decreases continuously by circa 0.1-0.2 °C per second and the heater can't keep up. (200 Watt heater). After 30 minutes I stopped the extrusion and the temperature was down to 270°C from 305°C.
I did choose 305°C as a starting temperature because I thought an extra buffer might help the PID/Heater to counteract the temperature decline.]]> ianmcmill Plastic Extruder Working Group Sun, 16 Mar 2014 13:55:44 -0400 https://reprap.org/forum/read.php?70,205005,325711#msg-325711 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,325711#msg-325711
Quote
ianmcmill
I just found your Masterbatch guide. Wonderful !!


I made some pictures of the filament and recorded an extrusion.

This is my extruder in action. The cracking sound of the pellets is nasty...
[www.youtube.com]

[attachment 28686 IMG_0820_web.jpg] This is the result of around 30 minutes extruding.

[attachment 28683 IMG_0825_web.jpg] Extrusion temp. around 270-280°C

[attachment 28684 IMG_0827_web.jpg] Extrusion temp. around 270-280°C

[attachment 28685 IMG_0830_web.jpg] Here you can see that the pellets are hollowed. May this cause those bubbles and ravels ?

Oh and I did not dry the pellets in the oven before.

And some questions:
1) What is your extrusion speed ? I am getting around 3m/min. That is 118"/min (for 2mm filament)
2) How fast is your motor running ? As it is a wiper motor, it has Speed 1 / 2 and "3" if you (or at least me) connect the speed 1 pin to ground and speed 2 to voltage in of the the motor.
3) Your nozzle diameter ? But I think I can recall you said something about 1mm.

You have a nice machine there!!! and I like your laser engraver!!

Temperature is to high - try anything from 190 to 210 for ABS then you will not have bubbles in the filament. At the moment you are boiling the plastic with temperatures higher than 260 C.
The hollow pellets should not be a problem and drying the pellets not needed under normal conditions.

My motor speed is about the same as yours.
My nozzle diameter is 1 mm for a 1.65 mm filament]]> Xabbax Plastic Extruder Working Group Sun, 16 Mar 2014 12:38:33 -0400 https://reprap.org/forum/read.php?70,205005,325424#msg-325424 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,325424#msg-325424
That filament looks awesome! This will serve me as a model !
I made some pictures of the filament and recorded an extrusion.

This is my extruder in action. The cracking sound of the pellets is nasty...
[www.youtube.com]

[attachment 28686 IMG_0820_web.jpg] This is the result of around 30 minutes extruding.

[attachment 28683 IMG_0825_web.jpg] Extrusion temp. around 270-280°C

[attachment 28684 IMG_0827_web.jpg] Extrusion temp. around 270-280°C

[attachment 28685 IMG_0830_web.jpg] Here you can see that the pellets are hollowed. May this cause those bubbles and ravels ?

Oh and I did not dry the pellets in the oven before.

And some questions:
1) What is your extrusion speed ? I am getting around 3m/min. That is 118"/min (for 2mm filament)
2) How fast is your motor running ? As it is a wiper motor, it has Speed 1 / 2 and "3" if you (or at least me) connect the speed 1 pin to ground and speed 2 to voltage in of the the motor.
3) Your nozzle diameter ? But I think I can recall you said something about 1mm.]]> ianmcmill Plastic Extruder Working Group Sat, 15 Mar 2014 15:42:42 -0400 https://reprap.org/forum/read.php?70,205005,325254#msg-325254 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,325254#msg-325254
I am now satisfied with my coupling and trying to get filament extruded. I have got some PC/ABS blend pellets with a processing temperature of 260-280 °C. Once the auger transports the pellets to the heater, the temperature drops from 280°C to 250°C and heats up again slowly.
The problem is that the fan is not enough to cool the filament quickly enough. Therefore the filalement ravels and sticks to the aluminium tube and although sliding into the fan (bad).
Here is a picture of the nozzle-part. From your experience, do you have any suggestion on how to improve this setup ?]]> ianmcmill Plastic Extruder Working Group Sat, 15 Mar 2014 09:12:25 -0400 https://reprap.org/forum/read.php?70,205005,323504#msg-323504 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,323504#msg-323504
Quote
ianmcmill
Thanks for the pictures Xabbax !

But I wonder what parts you used in picture F and G.
And how did you fasten the nut on the motor shaft.
Is this a square nut that connects the axis to the nut (from picture E) ??

I put a hex-nut onto the motorshaft and drilled a hole between the thread of the nut and shaft and put a 2mm steal bolt into it so that it doesn't loosen while driving the auger bit.

[attachment 28421 bolt.jpg]

First I used Loctite but this was not strong enough to keep up with the motor power.

Very good idea of you to fix the nuts to the motor shaft !!

I used a grinder to make a square nut from the hex nuts on the motor shaft to fit into the back of the socket.

The parts in picture F and G are steel tubes. The idea is not to have any force from the auger bit transfered to the motor shaft. I used a steel tube to keep the outer ring of the bearing a certain distance from the bracket where the motor is mounted. The socket can rotate freely inside the steel tube. The outer tube keeps the inner tube and the washer in position. I had to flare the outer tube to fit over the bearing You can use a plastic tube for the outside. I used what was available in my workshop at the time.]]> Xabbax Plastic Extruder Working Group Wed, 12 Mar 2014 03:22:14 -0400 https://reprap.org/forum/read.php?70,205005,323268#msg-323268 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,323268#msg-323268
But I wonder what parts you used in picture F and G.
And how did you fasten the nut on the motor shaft.
Is this a square nut that connects the axis to the nut (from picture E) ??

I put a hex-nut onto the motorshaft and drilled a hole between the thread of the nut and shaft and put a 2mm steal bolt into it so that it doesn't loosen while driving the auger bit.

[attachment 28421 bolt.jpg]

First I used Loctite but this was not strong enough to keep up with the motor power.]]> ianmcmill Plastic Extruder Working Group Tue, 11 Mar 2014 14:21:02 -0400 https://reprap.org/forum/read.php?70,205005,319375#msg-319375 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,319375#msg-319375
Quote
Bill Clark
micro processor controlled female companion that WE program:D

Where's the fun in that?]]> SheldonE Plastic Extruder Working Group Mon, 03 Mar 2014 23:05:32 -0500 https://reprap.org/forum/read.php?70,205005,319363#msg-319363 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,319363#msg-319363 Bill Clark Plastic Extruder Working Group Mon, 03 Mar 2014 22:27:57 -0500 https://reprap.org/forum/read.php?70,205005,319155#msg-319155 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,319155#msg-319155 See picture below. This describes it best.
[attachment 27911 coupling2.jpg]

It worked for some test runs but unfortunately my PWM motor controller died. So now the motor runs without controller. Full speed. What happened now is that the allen wrench went "nuts". The square inside the socket/nut quirled (?) and now the "allen wrench-coupling" turns loose.
Any suggestions ?
I have some more massive nuts (11mm for the auger + 13 mm for the motor) with a 13mm square socket. I could get a 13mm square solid steel rod.

I would be glad about any ideas !!!]]> ianmcmill Plastic Extruder Working Group Mon, 03 Mar 2014 14:16:31 -0500 https://reprap.org/forum/read.php?70,205005,279730#msg-279730 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,279730#msg-279730
Quote
hiliagusta
Steel tube length:200 mm (seamless stainless steel pipe)
OD:12.7 mm
ID: 10mm
Copper tube length: 80 mm - ordinary plumbers pipe
OD: 15 mm
ID: 13 mm
mm of overlapping between steel and copper tube: 10 mm
Oger length: 300 mm - cut to size that will fit your setup
Oger diameter: 10mm
Feed-window length: 25 mm
Feed-window width: 7.5 mm
Window distance from steel tube end: 50 mm
(Oger) mm of exceeding the steel tubes end: 0 mm
Distance between the ogers tip and the nozzles inner surface: 80-10 = 70 mm
Copper tube temperature at the end of warming up: not measured
Copper tube temperature during extruding: not measured
Aluminium heater block : 55 x 45 x 20 mm
Aluminium heatsink 65 OD ( I used a salvaged part from a motor found in an old tape recorder)

When you extrude for the first time feed the plastic into the heat chamber up to the nozzle and switch off the motor - wait for 15 - 30 minutes and then proceed.
Use a piece of wire through the nozzle to gauge the front of the plastic.
When you extrude and get a ripple effect on the filament your temperature is to low.
make sure that you allow enough time for the plastic to melt before you start the motor for extrusion. I lost a pipe and boke an auger bit when did not wait long enough and the motor distorted the stainless pipe at the feed window. I then made the feed window smaller to the current dimensions listed above.]]> Xabbax Plastic Extruder Working Group Sat, 14 Dec 2013 02:24:43 -0500 https://reprap.org/forum/read.php?70,205005,276113#msg-276113 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,276113#msg-276113 I find your extruder great, it works good and has no fancy or expensive parts!!! But there is still something, where I could use a bit help...: I write from Germany (I am greek), you know, a country well known for metal forming and machining... And because of the german mentality, I could never start building an extruder like yours, because I miss all the measurements! I would really be thankfull, if you could take the time to fill in a measurements list, because you know it yourself, reproducible results come from similar setups... How long is your steel tube, and how long the copper tube? What is the OD and ID of the 2 tubes?How wide is the overlapping between the steel and the copper tube? How long is your oger (23cm?), and what is the distance between the ogers tip, and the inner surface of the nozzles end? How wide and long is your feed-window, and at what distance from the tubes end does it beginn? Did you measure the temperature of the copper tube before starting the extrusion, so to say, when the copper tube is stillt empty, and the copper tube temperature when extruding, so to say when it is full? You write, that the oger gos 5-10mm in the hearing zone/copper tube: Do you mean the part of the copper tube overlappig with the steel tube, or does the oger exceeds the steel tube for about 5-10mm? Below I have a list, which you could use, so that everybody can see at a glance, what the matter is. I fill in already some gaps, whenever I thought that I have extracted the corresponding information from your postings. At last, please excuse my english, I have very little exercise. You will surely find a lot of mistakes!!! I would find it great, if everyone in the world could reproduce your extruder, no matter where he/she lives. Myself, I am a biochemist, but now unemployed, so I cannot buy an extruder, I have to build one on my own... :(
Steel tube length:
OD:
ID: 10mm
Copper tube length:
OD:
ID:
mm of overlapping between steel and copper tube:
Oger length:
Oger diameter: 10mm
Feed-window length:
Feed-window width:
Window distance from steel tube end:
(Oger) mm of exceeding the steel tubes end:
Distance between the ogers tip and the nozzles inner surface:
Copper tube temperature at the end of warming up:
Copper tube temperature during extruding:]]> hiliagusta Plastic Extruder Working Group Thu, 05 Dec 2013 07:00:09 -0500 https://reprap.org/forum/read.php?70,205005,268829#msg-268829 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,268829#msg-268829
Quote
ianmcmill
how did you join the bit with the motor ? can you make some pictures please ?
[attachment 21371 a.jpg]
[attachment 21372 b.jpg]

Cut the end of a cheap 9 mm socket for this part (image b.jpg)

[attachment 21373 c.jpg]
[attachment 21374 d.jpg]
[attachment 21375 e.jpg]
[attachment 21376 f.jpg]
[attachment 21377 g.jpg]
[attachment 21378 h.jpg]
[attachment 21379 i.jpg]]]> Xabbax Plastic Extruder Working Group Mon, 18 Nov 2013 12:55:39 -0500 https://reprap.org/forum/read.php?70,205005,267796#msg-267796 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,267796#msg-267796 vetteguy112233 Plastic Extruder Working Group Fri, 15 Nov 2013 22:38:45 -0500 https://reprap.org/forum/read.php?70,205005,264131#msg-264131 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,264131#msg-264131 vetteguy112233 Plastic Extruder Working Group Thu, 07 Nov 2013 20:58:01 -0500 https://reprap.org/forum/read.php?70,205005,261987#msg-261987 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,261987#msg-261987 ianmcmill Plastic Extruder Working Group Fri, 01 Nov 2013 13:14:50 -0400 https://reprap.org/forum/read.php?70,205005,249448#msg-249448 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,249448#msg-249448
I love the sds drill bit for the prime mover.

I wonder if we could add a second high temp chamber and a ram of some description and make a simplistic injection mould machine?

AS.]]> andysuth Plastic Extruder Working Group Sat, 28 Sep 2013 05:03:34 -0400 https://reprap.org/forum/read.php?70,205005,249424#msg-249424 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,249424#msg-249424 modesdo Plastic Extruder Working Group Sat, 28 Sep 2013 02:54:31 -0400 https://reprap.org/forum/read.php?70,205005,232798#msg-232798 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,232798#msg-232798 -------------------------------------------------------
> Has anyone tried multiple string extruder. Like
> instead of putting one hole on 1.75mm put more
> than one.

Yes I did - with two holes horizontally seperated about 8 mm. Extruding OK but the problem is the coiling of the filament on the floor. Getting a bit messy after a while.]]> Xabbax Plastic Extruder Working Group Mon, 05 Aug 2013 02:39:58 -0400 https://reprap.org/forum/read.php?70,205005,232531#msg-232531 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,232531#msg-232531 coolplastic Plastic Extruder Working Group Sun, 04 Aug 2013 03:21:27 -0400 https://reprap.org/forum/read.php?70,205005,231866#msg-231866 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,231866#msg-231866 Something like a mingun. :D]]> maboo Plastic Extruder Working Group Thu, 01 Aug 2013 17:10:04 -0400 https://reprap.org/forum/read.php?70,205005,231773#msg-231773 Re: Low cost 3D printing filament extruder for recycled plastics https://reprap.org/forum/read.php?70,205005,231773#msg-231773 coolplastic Plastic Extruder Working Group Thu, 01 Aug 2013 11:00:16 -0400