recycling processes

our processes in recycling

From corn to plastic waste, we turn it into 3D filaments to your 3D printer or products with our 3D farms, join our movement today to stop mass production of bad plastic products.

Biological

PLA is a biological plastic made out of mainly starch from corn or potatoes. Cornstarch, is a carbohydrate extracted from the endosperm of corn. This white powdery substance is used for many culinary, household, and industrial purposes. It was developed in 1844 in New Jersey.

Recycled

Many plastic products today like single use cutlery, straws and plastic glasses used in our everyday life can be recycled. We turn this into 3D filament together with our partner, Reflow in Holland. A defined and verified waste stream can turn into a valuable material for 3D printing, called rPLA (Recycled PLA)

Biodegradable

rPLA is biodegradable as it originates from corn or potatoes. We still do not want it to end up in rivers, beaches and oceans, as the natural process of breaking it down is far too long. We need to collect and treat it as a valued material as it can be recycled again or sent to proper facilities where it can be broken down.

Recyclable

rPLA is recyclable, both in its virgin form and even if it has been recycled. If the molecules are too damaged we can still make it into pellets and use other techniques like injection moulding to create new parts from it.

PLA is a bio and circular good way for many products like toys, interior, home, prototypes etc etc
Read more about plastic pollution Read more about recycling machines
the processes of recycling

From plastic waste to products

By running solar powered local lostboyslabs with 3D printers, we can stop the plastic waste entering our oceans. We create a circle of life for the plastic, we bring jobs and manufacturing local and we get people to become makers, creating parts and inventions that help daily life.
Recycling process for rPLA with 3D printers and filament

This process uses biodegradable PLA, we can create 3D filaments from your local waste stream and together with our community turn it into 3D filaments that will then be used for 3D farms. The waste stream can be local, but we will create the 3D filament in Europe and send back to the 3D farms. Transports will be Co2 compensated.

Step 1

Corn Starch is used for biological plastic

Corn is born

Step 2

Plastics used, waste stream collected

Recycling and waste stream is sent to partner Reflow

Step 3

3D Filament is made out of the waste that is recycled

With our partners Reflow in Holland we create rolls of rPLA

Step 4

3D printers manufacture the digital 3D CAD model

3D model is downloaded from whatt.io and sent to printer

Step 5

Parts are assembled and product is ready!

Light fitting for pending lamp
Recycling process for rPET with shredders & 3D printers

This process uses PET bottles as source, where the whole recycling process is done locally. 3D filaments from your local waste stream of PET is used and local products can be made with 3D printers or injection moulding (the mould is the 3D printed).

Step 1

PET bottles are collected locally

Collection process

Step 2

Shredding plastic into pellets

The process is local and creates plastic pellets

Step 3a (for injection moulding)

3D printers print the model or the mould is made earlier from 3D printers for injection moulding(3a)

The mould process is made with industrial 3D printers in high temperature plastic materials like PEEK or PPSU

Step 3b (for creating 3D filaments)

Pellets extruded and transformed to 3D filament

This process requires good plastic stream but allows for 3D printing with standard FDM printers

Step 4a (injection moulding)

Pellets enters extruder for injection mould (3a)

Moulds made in step 3a with industrial printers, downloaded digital moulds from whatt.io, then extruded into a injection mould machine.

Step 4b (3D printing w 3D filaments)

3D printers manufacture the digital 3D CAD model

3D model is downloaded from whatt.io and sent to printer

Step 5

3D printed part or injection moulded part is ready!

Same part is created in two different ways as above (a & b) depending on local factors as well as quality of plastic.
a new way to recycle

the resin codes of the present is the past

An industry that needs to be challenged

The Resin Identification Code system is not detailed enough, does not support variations, composites, sources, traceability or bio-plastics at all. Biodegradable PLA is just put into category 7 among others. It is very bad to mix bioplastics or biodegradable ones with other petrolium based plastic when recycling. It is high time to challenge the whole industry and demand a better coding system for a proper circular handling of the material so we know what we are dealing with. A proper system that manages the product form cradle to grave and allow a material passport will be the way moving forward.


At lostboyslab we made our own symbol for sustainable recycling and re-printing materials into new products (made with 3D printers). We have the ability to recycle, create new 3D materials and then use 3D printing or injection moulds (made by 3D printers) to create new parts from old plastic. That is recycling and re-use of material.

rPLA and rPET is recycled materials, rPLA is made out of corn starch and is biodegradable and compostable (the definition varies from different countries)

Regardless, no plastic waste should ever end up in landfill, oceans or be burnt. It can be recycled and turned into new products with shredders, extruders and 3D material machines.