Science & Research
The scientific foundation of our bottle-to-filament technology
Research Status
Our research is ongoing as we develop and refine our technology. This page presents the scientific principles guiding our work and the research directions we're pursuing. As high school students, we're learning and growing through this process, consulting with experts and conducting our own experiments.
The Materials Science Challenge
Converting plastic bottles into high-quality 3D printing filament presents several materials science challenges. PET (Polyethylene Terephthalate) plastic, commonly used in beverage bottles, has different properties when recycled compared to virgin material. Our research focuses on understanding and addressing these differences.
Polymer Chain Length
The molecular structure of PET consists of long polymer chains. During the initial manufacturing and subsequent recycling processes, these chains can break, resulting in shorter chain lengths. This affects:
- Mechanical strength
- Melting temperature
- Flow behavior during printing
- Crystallization rate
Our ribbon-cutting approach aims to preserve more of the original polymer structure compared to methods that completely melt and re-extrude the plastic.
Crystallinity and Thermal History
PET bottles are typically highly crystalline due to the manufacturing process (stretch blow molding). This crystallinity affects:
- Transparency
- Rigidity
- Heat resistance
- Processing temperature requirements
We're researching optimal heating and cooling profiles to control crystallization during our filament production process, aiming for consistent printing behavior.
Our Research Methods
Material Characterization
We're establishing baseline properties for different types of PET bottles through:
- Tensile strength testing
- Differential scanning calorimetry (DSC) to assess thermal properties
- Melt flow index (MFI) measurements
- Transparency and coloration analysis
These tests help us understand the starting material and how our processing affects its properties.
Process Optimization
We're using design of experiments (DOE) methodology to systematically investigate:
- Optimal ribbon dimensions for consistent feeding
- Temperature profiles during extrusion
- Cooling rate effects on filament properties
- Tension and drawing effects during spooling
By carefully controlling and documenting these variables, we're identifying the conditions that produce the highest quality filament.
Print Testing
The ultimate test of our filament is how it performs in actual 3D printing applications. We evaluate:
- Layer adhesion strength
- Surface finish quality
- Dimensional accuracy
- Print success rate
- Post-printing mechanical properties
We use standardized test objects and printing parameters to make valid comparisons between different filament batches and against commercial products.
Collaborative Research
As high school students, we recognize the value of collaboration with experienced researchers and institutions. We're developing relationships with:
- University materials science departments
- Local makerspaces and 3D printing labs
- Plastic recycling experts
- Environmental research organizations
These collaborations provide access to advanced testing equipment, expert guidance, and opportunities to share our findings with broader scientific communities.
Future Research Directions
As our project develops, we plan to expand our research into:
Additives and Blends
Investigating additives to enhance recycled PET properties and exploring blends with other recycled plastics.
Bottle Contaminants
Studying the effects of common contaminants (labels, adhesives) and developing better removal/filtering methods.
Multiple Recycling Cycles
Examining how repeated recycling affects filament properties and developing methods to maintain quality over multiple cycles.
Energy Efficiency
Optimizing our process to minimize energy consumption while maintaining product quality.
Alternative PET Sources
Expanding beyond bottles to other PET waste streams like food containers and packaging.
Life Cycle Assessment
Conducting comprehensive analysis of environmental impacts compared to virgin filament production.
Research Collaboration Opportunities
If you're a researcher, educator, or industry professional interested in our work, we welcome opportunities for collaboration, mentorship, or resource sharing. Our project is open-source, and we believe in the power of collective problem-solving and knowledge sharing.