Polymaker, a leading manufacturer of 3D printing materials, used Covestro's recycled polycarbonate to develop a polycarbonate wire called Polymaker™ PC-r. The raw material comes from a 19-liter bucket of Nongfu Spring which contains high-purity polycarbonate. Covestro is responsible for mixing plastic waste with virgin materials to produce recycled polycarbonate base materials. Subsequently, the base material is made into a wire through an extrusion process and becomes a 3D printing material used in the electronics, automobile and other industries.
By combining the application of 3D printing technology in industrial-scale production, this material can provide strong support for brands looking to build a more sustainable supply chain. Compared with virgin materials, wires made from recycled materials have a smaller carbon footprint. The product is also more durable and meets the requirements of specific industries, such as Blue Angel and EPEAT (Electronic Product Environmental Assessment Tool) certification.
A single source of recycled materials is also an advantage, which means that there is no need to sort and identify plastics in advance. Plastic waste is of high purity and can be recycled in a cost-effective way. In addition, adequate supply is also very important. In China, the use of bottled water in households and public places is very common. After repeated collection and filling, the bucket finally reaches the waste standard and can be recycled and reused. This is another case of Covestro and value chain partners building a circular economy.
This high-temperature-resistant post-consumer recycled polycarbonate has excellent thermal stability and mechanical strength. Based on these characteristics, it is necessary to use a printer with a heat preservation cavity.
The 3D printer manufacturer INTAMSYS used the FUNMAT PRO 410 printer to test the Polymaker™ PC-r. The temperature of the dual nozzles of this printer can reach 500°C, and the temperature of the bottom plate can reach 160°C. In addition, the temperature of the heat preservation chamber can reach 90°C, which can prevent the prints from warping and can print larger and more complex models.
The test results show that Polymaker™ PC-r is very easy to process and performs well in performance indicators such as tensile strength, Young's modulus, flexural strength and flexural modulus, which are slightly higher than standard polycarbonate.