In early 2021 I decided that I was going to try to produce formwork (for poured structures such as concrete) out of recycled plastic bricks. This was in part because I'd heard that there's timber shortages, a crisis in plastic recycling, and I always wanted to figure out what to do with my waste 3D prints. In discussions with concreters and other builders who use formwork, I was told that the resulting surface finish of the structure was a very important consideration when selecting a material for formwork. This is why formply, with it's smooth exterior laminate is the industry standard, even if it rapidly becomes a waste product.
This lead me to come up with higher specifications for tolerances & surface quality than the original, open source brick tooling designed by Precious Plastic. However I was determined that the geometry of their brick was still suitable for formwork, with the addition of a compression step, and more precise (machined rather than welded) parts.
As a result I started work late last year in building a
PrintNC specced to my project, with hardware that I am familiar with (Duet). This week, using steel I milled and cut on the PrintNC I was able to produce my first "early production brick"*.
The mould's design is simple to replicate, costs less than $300aud, $200usd, 170gbp, etc. and can produce bricks without additional tooling, with nothing more than your body weight and some** heat.
I'm seeking feedback on the project, and hopefully some people interested in replicating it.
*that didn't break into pieces as I demoulded it.
**understatement.
I've uploaded the current design here:
https://www.thingiverse.com/thing:5467974
Edited 2 time(s). Last edit at 08/19/2022 01:59AM by MortarArt.