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Felfil EVO extruder
Felfil started out as a master’s degree project in EcoDesign at the Polytechnic of Turin, Italy. The passion for 3D printing and sustainable design gave rise to the EVO plastic extruder, first promoted in 2015 with a Kickstarter campaign. Since then the Felfil recycling kit has been expanded with two more devices - the spooler and the plastic shredder.
Plastic was first invented at the beginning of the 20th century, and it didn’t take long before it was commercialized and took the world by storm. Plastic is a very versatile and useful material, but it is also the source of a lot of waste and pollution. The Felfil EVO extruder is the answer to that problem on a domestic scale but with a lot of potential for big changes.
The Felfil Evo extruder is an open source Arduino based device. It comes already assembled and ready to use, which makes it the perfect entry level extruder. The package includes a material sample of about 400 g. The extruder itself is small (350 x 180 x 180 mm) and light (around 5 kg), which makes it fit onto a standard office desk or even a small table.
The printed circuit board is designed to be safe for home conditions - the accepted voltage is the standard range of 110-230 V found in the sockets at any house. The EVO extruder is sustainable as it only consumes between 80-180 W of energy, which is more or less what a desktop computer uses.
The hopper can fit up to 1 L (approx. 330 g) of material - pellets or shredded plastic, such as failed prints, removed support materials or bottle caps. It is as easy as setting the speed and temperature, introducing the material and extruding. Many materials were tested on the EVO extruder and the compatible plastics were found to be PLA, ABS, HIPS, PETG, PA (6,12), PMMA, HDPE, LDPE, TPU, TPE and PVA. The EVO extruder can work at temperatures of up to 300 ºC, which makes it appropriate for extruding all the above mentioned materials. This allows the user to experiment almost without limits.
The secret of the great compatibility of the EVO extruder with so many distinct materials lies in the powerful gear motor and a special extruding screw. The Felfil Evo gearmotor performs up to 9 revolutions per minute. Its strength and reliability are what powers the extruding screw, allowing the EVO extruder to efficiently mix various materials.
The extruding screw, made from K100 steel, was designed to mix plastic scraps to perfection, producing new custom filament at a rate of 1.15 m/minute.
Another convenient feature of the EVO extruder is that it allows for easily changing between 1.75 mm and 2.85 mm nozzles, which lets the user make filaments of different diameters. A video on how to change the nozzle can be found in the Usage tips section.
It is possible to make colored filament with the EVO extruder - both with pellets and plastic scraps. To make a colored filament using pellets, a mix of a polymer base and a color masterbatch in the desired proportions must be introduced into the catchment area of the shredder (keeping in mind the maximum capacity of the hopper).
Then, the temperature and speed of extrusion have to be set and the mix is ready to be extruded. The manufacturer urges not to use materials of unknown composition, various polymers together or abrasive additives. It is also advised to clean out the brand new extruder by extruding a testing batch, since at first the filament may contain metal shavings.
The Felfil EVO extruder can be used together with the plastic shredder and the spooler as part of a standalone recycling kit. With this set, it is possible to shred plastic, extrude it into filament and wrap it onto a spool that is then ready to use on a 3D printer.
The EVO extruder is a compact, safe and intuitive device that allows the users of desktop 3D printers to produce custom filament in a quick, affordable and sustainable way in home conditions, with no need for specialist equipment or a professional workspace.
There is a series of rules that should be followed when using the EVO plastic extruder:
Following those rules will ensure that the EVO extruder functions properly and safely. Should the extruder exhibit any atypical behavior or signs of malfunction, the manufacturer should be contacted.
The EVO plastic extruder already comes assembled but a few simple steps should be followed to properly plug it and prepare it for use. These steps are explained in a video provided by the manufacturer:
The manual (Downloads section) should be inspected closely before the EVO extruder is used for the first time. It should also be made sure that the on/off button is in the off position before the extruder is plugged into the socket.
The EVO extruder can use 1.75 mm and 2.85 mm nozzles. The process of changing them is quite straightforward. It is demonstrated in a short video by Felfil.
The nozzle must be carefully unscrewed from the main frame of the device, and the new nozzle must be installed in its place (always with an O-ring).
For further technical information and safety recommendations, see the documents in the Downloads section.
A versatile open source desktop plastic extruder. Works with pellets and plastic scraps.