ReDeTec ProtoCycler - User Manual

Operations Manual
Rev. 1.3

Summary

1.0 Introduction to the ProtoCycler

1.1 Safety

General safety guidelines for operating ProtoCycler.

1.1.2 Extrusion Safety

Specific safety precautions for the extrusion process.

1.2 ProtoCycler Layout

Overview of the ProtoCycler's physical components and terminology.

2.0 Grinding

2.1 Grinder Operation

Detailed steps and considerations for operating the grinding unit.

2.1.1 Grinder Safety

Crucial safety warnings and precautions for grinder use.

2.1.2 Grinder First Time Setup

Instructions for the initial assembly and setup of the grinder.

2.1.3 Operation

Step-by-step guide on how to operate the grinder.

2.2 Sorting Ground Material

Method for sorting ground plastic particles by size for extrusion.

2.3 Regrind Size & Extruding Recycled Plastic

Guidelines on regrind particle size and mixing with virgin plastic.

3.0 Important Things to Know Before Extruding

3.1 Puller Wheel Storage

Proper storage of the puller wheel to prevent flat spots.

3.2 Cleanliness

Importance of keeping the ProtoCycler clean for optimal performance.

3.3 Plastic Care: Dry vs Wet - Clean vs Dirty

Procedures for drying and storing plastic before extrusion.

3.4 Opaque vs Transparent Plastic

Limitations regarding transparent plastics and colorant use.

3.5 Spooler Set Up

Instructions for assembling the filament spooler.

3.5.1 Spooler Assembly Instructions

Detailed steps for assembling the ProtoCycler spooler unit.

3.6 Light Guide Alignment

3.6.1 What you need to check Light Guide Alignment

Tools and software required for light guide alignment.

3.6.2 Light Guide Alignment Overview

Understanding the purpose and process of light guide alignment.

3.6.3 Step 1 - Adjusting the sensor height

First step in alignment: adjusting sensor height with thumbscrews.

3.6.4 Step 2 - Evenly lighting the sensor

Aligning LEDs to ensure even light distribution across the sensor.

3.6.5 Step 3 - Calibrating the readings

Final calibration step using dowels to ensure accurate diameter readings.

4.0 Extrusion Operational Instructions

4.1 Overview

Introduction to extrusion modes and preparation steps.

4.2 Initial Extrusion Steps for both Manual and Automatic

Preliminary steps before starting any extrusion process.

4.3 Automatic Extrusion

Guide to operating the ProtoCycler in automatic extrusion mode.

4.3.1 Automatic Extrusion Steps

Detailed sequence of operations for automatic extrusion.

4.4 Manual Extrusion

Instructions for manual extrusion control.

4.4.1 Manual Extrusion Steps

Step-by-step instructions for manual extrusion control.

5.0 Intro to the ProtoCycler Purge Procedure (PPP)

5.1 Purging

General introduction to purging the ProtoCycler system.

5.1.1 Short Purge

Procedure for a short purge, e.g., color changes.

5.1.2 Disco Purge

Procedure for disco purging for material transitions.

5.3 Purge Tips

Best practices and advice for effective purging.

6.0 Congratulations!

7.0 Appendix

Overview

1. Function Description
2. Usage Features
3. Grinding Operation
4. Sorting Ground Material
5. Extruding Recycled Plastic
6. Plastic Care (Drying and Cleanliness)
7. Opaque vs. Transparent Plastic
8. Spooler Setup
9. Light Guide Alignment
10. Extrusion Operational Instructions (Manual and Automatic Modes)
11. Initial Extrusion Steps (Both Modes)
12. Automatic Extrusion Steps
13. Manual Extrusion Steps
14. Maintenance Features
15. Cleanliness
16. Nozzle Clogging
17. Puller Wheel Storage
18. Purge Procedure (PPP)
19. Purge Tips

The ProtoCycler is an advanced extrusion system designed to provide an easy-to-use experience for recycling and filament creation. It features an automated control system to monitor and manage the extrusion process, making it suitable for both novice and experienced users. The device allows users to experiment with new materials and colors through its software, offering flexibility in filament production.

Function Description

The ProtoCycler primarily functions as a plastic recycling system that grinds plastic waste and extrudes it into filament for 3D printing. The process involves several key stages: grinding, sorting, drying, and extrusion. The device is equipped with a grinder for breaking down plastic parts, a sorting mechanism to ensure appropriate particle size for extrusion, and an extruder that melts and forms the plastic into filament. A spooler system then winds the extruded filament onto spools.

Usage Features

Grinding Operation:

The ProtoCycler's grinder is powered on at all times during operation and relies on an electromagnet interlock for safety. This interlock engages the grinder drive train only when power is supplied and disengages at a set torque limit to prevent damage. The grinder operates only when both the grinder lid and drawer are correctly engaged. Users can place plastic parts into the grinder hopper, secure the lid, and then operate the grinder handle. If the load exceeds the maximum, the interlock disengages, requiring the user to reverse the grinder and reduce the load.

Sorting Ground Material:

After grinding, the material needs to be sorted to ensure optimal particle size for extrusion. The grinder drawer contains a sorting mechanism with two levels of offset holes that sift ground material. Users lift the sorting mechanism, shake it to allow smaller particles to fall through, and then re-grind any oversized bits. Proper cleaning of the catch container for sorted material is crucial to avoid contamination.

Extruding Recycled Plastic:

The size of regrind particles is critical for preventing jams. The ProtoCycler's extruder accepts pellets between 0.125" and 0.2" in diameter, with an Extruder Hopper Filter providing a final safeguard against oversized particles. It is recommended to mix regrind with virgin pellets, with a 50% recycled plastic ratio being ideal, though up to 70% can be successful with well-ground material. Extruding 100% regrind is not recommended due to the risk of jamming.

Plastic Care (Drying and Cleanliness):

Plastic must be dry and clean before extrusion, as moisture can cause bubbles and affect filament quality. The ProtoCycler supports PLA and ABS, with specific drying temperatures and times provided (e.g., 80°C for PLA and 80-90°C for ABS, both for 4 hours). Dried plastic should be stored in airtight containers with desiccants to prevent reabsorption of moisture. The extruder hopper should also be inspected for dust and contaminants before use.

Opaque vs. Transparent Plastic:

The diameter sensors used for control require opaque filaments. For naturally transparent plastics like PLA, colorants must be added to make the filament opaque for proper sensor readings.

Spooler Setup:

The spooler system needs to be assembled and configured before extrusion. This involves sliding the spooler shaft, spacer, and spool hubs into position, securing them, and then inserting the assembly into the ProtoCycler's base. The spooler motor is then plugged in, and spool geometry settings (width and diameter) are configured via the ProtoCycler's User Interface.

Light Guide Alignment:

Accurate light guide alignment is essential for the ProtoCycler's vision system to verify and maintain filament diameter. This involves adjusting the sensor height using thumbscrews and ensuring the LED light evenly illuminates the sensor. The process includes aiming the LED up or down by loosening and tightening screws or adjusting a shaft knob, depending on the light guide version. Calibration is performed using dowels of known diameters (e.g., 1.83mm for the puller sensor and 2.56mm for the nozzle sensor) to ensure accurate readings. The graphical user interface (GUI) helps monitor raw data to confirm proper alignment, showing a "U-shaped" trough when a dowel is in place.

Extrusion Operational Instructions (Manual and Automatic Modes):

Before starting extrusion, the spooler must be correctly set up. The ProtoCycler should be operated in a clean, dry environment at ambient air temperature (~23°C). The unit is primed with plastic and calibrated before shipping, but purging may be required to flush out old plastic if it has absorbed moisture.

Initial Extrusion Steps (Both Modes):

1. Fill the hopper with dry plastic and colorant (if needed).
2. Power on the ProtoCycler and choose whether to connect to a computer.
3. Navigate to the "Extrude" screen on the ProtoCycler and select either "Automatic" or "Manual" mode, then "Begin Extrusion."

Automatic Extrusion Steps:

1. The ProtoCycler preheats to thermalization temperature, holding for 100 seconds to ensure a uniform melt section temperature.
2. It then preheats to the selected plastic's extrusion temperature (PLA or ABS by default).
3. Once "Filament Ready" is displayed, users use tweezers or pliers to feed the plastic from the nozzle through the puller wheels, ensuring the puller wheel idler spring is engaged. A 2-minute timeout feature is in place for safety.
4. The device enters "Stabilization" phase, where it waits for consistent filament diameter before spooling.
5. When "Spooler Ready" is displayed, the fan speed reduces, and users snip excess filament, feed it through the spreader guide, and tape it to the spool.
6. Once taped, selecting "Spooler Ready" initiates the spooling process, with the control system taking over to maintain consistent filament diameter.

Manual Extrusion Steps:

1. After selecting "Begin Extrusion," the ProtoCycler awaits commands. Users must manually heat up and begin extrusion.
2. The temperature sensor is set to the desired thermalization temperature (e.g., 175°C for PLA, 210°C for ABS).
3. The lower pressure bound is disabled by entering "pl000000" in the command line.
4. The auger speed is set to 30 via the slider.
5. The melt section thermalizes for 100 seconds.
6. The extrusion temperature preheat begins (e.g., 181-187°C for PLA, 220-230°C for ABS).
7. Once plastic flows correctly, the lower pressure bound is reset to "pl000050."
8. The fan is turned on using the slider (e.g., 40 for PLA, off for ABS) to soften the plastic for spooling.
9. The puller wheel idler arm spring is attached, and pull speed is set to ~30-40.
10. Plastic is fed from the nozzle through the puller wheels using tweezers or pliers.
11. For spooling, filament is taped to the spool, fed through the spreader guide, and "ss000000" is entered to start spreading the filament.
12. Fan speed is increased (100% for PLA, 50% for ABS).
13. Diameter control is enabled by sliding the diameter slider to the desired filament size.

Maintenance Features

Cleanliness:

Regular cleaning of the ProtoCycler is important to prevent defects in output filament. The extruder hopper should be inspected for dust and contaminants. Compressed air ("computer duster") is recommended to clear dust from the light sensors. A soft material, like a skinny piece of PLA filament, can be used to clean the photoresistor slot. Metal or sharp objects should never be used to clean the diameter sensors to avoid permanent damage.

Nozzle Clogging:

If un-meltable or dissimilar materials enter the system, the nozzle may become clogged. The Nozzle Cap contains a breaker plate and screen to build stable pressure and act as a defense against contaminants. If the screen becomes clogged, users should contact ReDeTec support for assistance, as this process requires special care and safety.

Puller Wheel Storage:

The puller wheels have soft silicone tires that can develop flats if left stationary under pressure for extended periods. To prevent this, it is important to disengage the spring and rotate the puller idler wheel out of position when the device is not in use.

Purge Procedure (PPP):

Purging is necessary for transitioning between different plastics or colors.

• Short Purge: Used for transitioning between wet and dry plastic or color changes. This involves powering on, connecting to PCC, disabling the lower auger speed limit, setting preheat temperature, setting auger speed to 50, thermalizing the melt section, increasing temperature to purge temperature, increasing auger speed to 75, and purging for 10-15 minutes until the new plastic fully transitions. Melted plastic should be carefully removed from the Garbage Shoot using PPE and pliers.
• Disco Purge: Used for material changes, involving thermal cycling to transition from one material to another. It is strongly recommended to remove nozzles for the duration of a disco purge and replace them with new ones once purging is complete. The process involves removing the nozzle, following steps 1-8 of a short purge, then setting temperature to 0°C and auger speed to 50, increasing temperature back to purge temperature once the extruder cools to the lower temperature material's nozzle removal temperature, increasing auger speed to 75, and purging for 10 minutes. This cycle is repeated until the new material is fully transitioned.

Purge Tips:

• Purging, especially from warmer to cooler temperature plastics, can be time-consuming, so avoiding frequent material switches is advisable.
• Using different colorants helps distinguish between old and new plastic during purging.
• When purging dissimilar materials, users should consult MSDS documentation for extrusion temperature overlaps to avoid burning material or clogging the extruder. If no overlap exists, technical support should be contacted for advice on intermediary purge materials.
• Having an extra nozzle (with breaker plate and screen) is useful for preventing contamination when switching materials.

ReDeTec ProtoCycler Specifications

General

Filament Diameter	1.75mm
Output Material	3D printer filament
Supported Materials	ABS, PLA, PETG
Connectivity	USB
Nozzle Diameter	0.4mm
Input Material	Plastic
Power Requirements	110-240V, 50/60Hz