Overview

This open-source product collection presents the demonstrative application parts used to evaluate the printability and performance of recycled PC and PC-ABS blends on a modified large-format pellet-based 3D printer equipped with a custom extrusion system. It includes the two proof-of-concept products: a modular coat-hanger joint from the furniture sector and a customizable protective shin guard from the sports sector. Their geometries were developed to challenge material flow consistency, overhang fidelity, pattern stability, and dimensional accuracy using fused granular fabrication. These application models demonstrate the feasibility of using high-performance recycled feedstocks, typically difficult to recycle or print at large scale, validating the potential of the modified pellet extruder and the overall system for distributed recycling and large-format additive manufacturing. 1

Materials and Tools

• ⚙️ 3D modeling: Fusion 360 (application design, furniture) 2 and Grasshopper (application design, sports) 3 .
• 🔩 Slicing and fabrication: PrusaSlicer 4 , Large-format Fused Granular Fabrication 3D Printer (3D printed product applications).
• 📎 Materials: PC-ABS tested for the product applications. Other materials available for some components (Furniture).
• 🔩 Additional off-the-shelf: to be added to the product for the intended use (Please refer to the documentation in the repository). Additional 3D printed TPU part or off-the-shelf soft pad to be added to the sport protection part.
  
  
  

Repository website