Quality Control
How we ensure consistent, high-quality filament from recycled plastic
Development Status
Our quality control systems are currently under development as we build and refine our prototype. The standards and processes described below represent our goals and the framework we're implementing to ensure excellent filament quality.
Our Quality Challenge
Creating high-quality 3D printing filament from recycled plastic bottles presents unique challenges. Unlike manufacturing with virgin materials, we work with plastic that has already been processed once and may have various additives or contaminants. Our quality control process is designed to address these challenges while maintaining sustainability.
Our Quality Assurance Process
Raw Material Selection
Not all plastic bottles are created equal. We carefully select input materials, focusing on clear PET bottles with minimal additives. We avoid bottles with certain dyes, labels, or chemical coatings that could affect filament quality.
- Visual inspection of all incoming bottles
- Sorting by plastic type, clarity, and condition
- Rejection of heavily degraded or contaminated materials
Cleaning Protocol
Thorough cleaning is essential for quality filament. Our cleaning process removes labels, adhesives, and contaminants that could interfere with extrusion or affect print quality.
- Washing with biodegradable detergents
- Label and adhesive removal
- Thorough drying to prevent moisture issues
- Final inspection before processing
Precision Cutting
Our ribbon-cutting technology is calibrated for consistent output, which is crucial for the extrusion process. We monitor and adjust cutting parameters for different bottle types and thicknesses.
- Regular calibration of cutting mechanisms
- Monitoring of ribbon dimensions
- Adjustment for different PET thicknesses
- Quality checks at transition points (bottle neck, base)
Extrusion Parameters
The heart of our quality control is the extrusion process. We carefully control temperature, pressure, and cooling to produce filament with consistent diameter and mechanical properties.
- Precise temperature control throughout the heating zones
- Regular diameter measurement
- Controlled cooling rate for optimal crystallization
- Tension monitoring during spooling
Testing Protocol
Each batch of filament undergoes rigorous testing to ensure it meets our quality standards. We test for physical dimensions, mechanical properties, and print performance.
- Diameter consistency testing (±0.05mm tolerance goal)
- Tensile strength and flexibility measurements
- Moisture content verification
- Actual 3D printing tests with standard models
- Layer adhesion and surface quality evaluation
Quality Standards
As we develop our technology, we're working toward meeting or exceeding these quality standards for our filament:
| Parameter | Target Specification | Testing Method |
|---|---|---|
| Diameter | 1.75mm ± 0.05mm | Micrometer measurements every 10cm |
| Roundness | ≥ 95% | Filament is run through a lasercut template |
| Moisture Content | ≤ 0.03% | Filament is run through a filament |
Commitment to Continuous Improvement
Quality control is an ongoing process. We're constantly learning and refining our methods to improve our filament quality while maintaining our sustainability goals. We welcome feedback from users and are developing relationships with materials science experts to enhance our processes.