3-D Printing Using Shredded Milk Jugs

Joshua Pearce's group cleans plastic milk jugs, removes the labels and shreds them into plastic before turning them into plastic filament for 3D printers. 

Credit: Image courtesy of Michigan Technological University

Suppose you could replace "Made in China" with "Made in my garage."

Suppose also that every time you polished off a jug of two percent, you would be stocking up on raw material to make anything from a cell phone case and golf tees to a toy castle and a garlic press.

And, you could give yourself a gold medal for being a bona fide, recycling, polar-bear-saving rock star.

Michigan Technological University's Joshua Pearce is working on it. His main tool is open-source 3D printing, which he uses to save thousands of dollars by making everything from his lab equipment to his safety razor.

Using free software downloaded from sites like Thingiverse, which now holds over 54,000 open-source designs, 3D printers make all manner of objects by laying down thin layers of plastic in a specific pattern.

While high-end printers can cost many thousands of dollars, simpler open-source units run between $250 and $500 -- and can be used to make parts for other 3D printers, driving the cost down ever further.

"One impediment to even more widespread use has been the cost of filament," says Pearce, an associate professor of materials science and engineering and electrical and computer engineering.

Though vastly less expensive than most manufactured products, the plastic filament that 3D printers transform into useful objects isn't free.

Milk Jugs
Milk jugs, on the other hand, are a costly nuisance, either to recycle or to bury in a landfill. But if you could turn them into plastic filament, Pearce reasoned, you could solve the disposal problem and drive down the cost of 3D printing even more.

So Pearce and his research group decided to make their own recycling unit, or RecycleBot. They cut the labels off milk jugs, washed the plastic, and shredded it.

Then they ran it through a homemade device that melts and extrudes it into a long, spaghetti-like string of plastic. Their process is open-source and free for everyone to make and use at Thingiverse.com.

The process isn't perfect. Milk jugs are made of high-density polyethylene, or HDPE, which is not ideal for 3D printing. "HDPE is a little more challenging to print with," Pearce says, but the disadvantages are not overwhelming.

His group made its own climate-controlled chamber using a dorm-room refrigerator and an off-the-shelf teddy-bear humidifier and had good results. With more experimentation, the results would be even better, he says. "3D printing is where computers were in the 1970s."



The group determined that making their own filament in an insulated RecycleBot used about 1/10th the energy needed to acquire commercial 3D filament.

They also calculated that they used less energy than it would take to recycle milk jugs conventionally.

3-D Printing: Ears Look and Act Like the Real Thing

A 3-D printer in Weill Hall deposits cells encapsulated in a hydrogel that will develop into new ear tissue. 

The printer takes instructions from a file built from 3-D photographs of human ears taken with a scanner in Rhodes Hall. 

(Credit: Lindsay France/University Photography)

Cornell bioengineers and physicians have created an artificial ear -- using 3-D printing and injectable molds -- that looks and acts like a natural ear, giving new hope to thousands of children born with a congenital deformity called microtia.

In a study published online Feb. 20 in PLOS One, Cornell biomedical engineers and Weill Cornell Medical College physicians described how 3-D printing and injectable gels made of living cells can fashion ears that are practically identical to a human ear.

Over a three-month period, these flexible ears grew cartilage to replace the collagen that was used to mold them.

"This is such a win-win for both medicine and basic science, demonstrating what we can achieve when we work together," said co-lead author Lawrence Bonassar, associate professor of biomedical engineering.

The novel ear may be the solution reconstructive surgeons have long wished for to help children born with ear deformity, said co-lead author Dr. Jason Spector, director of the Laboratory for Bioregenerative Medicine and Surgery and associate professor of plastic surgery at Weill Cornell in New York City.

"A bioengineered ear replacement like this would also help individuals who have lost part or all of their external ear in an accident or from cancer," Spector said. Replacement ears are usually constructed with materials that have a Styrofoam-like consistency, or sometimes, surgeons build ears from a patient's harvested rib. This option is challenging and painful for children, and the ears rarely look completely natural or perform well, Spector said.

To make the ears, Bonassar and colleagues started with a digitized 3-D image of a human subject's ear, and converted the image into a digitized "solid" ear using a 3-D printer to assemble a mold.

This Cornell-developed, high-density gel is similar to the consistency of Jell-o when the mold is removed. The collagen served as a scaffold upon which cartilage could grow.

The process is also fast, Bonassar added: "It takes half a day to design the mold, a day or so to print it, 30 minutes to inject the gel, and we can remove the ear 15 minutes later. We trim the ear and then let it culture for several days in nourishing cell culture media before it is implanted."

The incidence of microtia, which is when the external ear is not fully developed, varies from almost 1 to more than 4 per 10,000 births each year. Many children born with microtia have an intact inner ear, but experience hearing loss due to the missing external structure.

Reference
High-Fidelity Tissue Engineering of Patient-Specific Auricles for Reconstruction of Pediatric Microtia and Other Auricular Deformities, 2013; 8 (2): e56506 DOI:10.1371/journal.pone.0056506