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DesignLab Builds: Heat Press

2022 Hackaday Prize Recycling Machines Inspo

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We used the inspiration of the hydraulic Precious Plastic Sheet Press, to develop our own miniaturized version of their appliance that better fits in the footprint of our space.  With this equipment we will have the capability to be able to convert discarded plastic (bottles,  containers, bags) into reusable plastic panels.

Instead of building an entire machine from scratch, we utilized a premade hydraulic 20-Ton Shop Press as the main component in the apparatus and focused on prototyping the heating platens.  Using this scaled down version allows for frames to press a sheet size as large as 18” x 24”.

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SFDL_SheetPress_12x12_frame.step

12" x 12" x .375" inside frame dimensions mold

step - 54.65 kB - 05/03/2022 at 21:47

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  • 1 × https://www.harborfreight.com/20-ton-shop-press-32879.html 20 Ton H-Frame Floor Shop Press; $250 USD
  • 18 × Ins. Strip Heater, 120V, 6 in. L, 900 Deg F; $40 USD, (x6) $720 USD https://www.zoro.com/tempco-ins-strip-heater-120v-6-in-l-900-deg-f-msh02260/i/G2033193/
  • 4 × Ebox Enclosure BUD Industries CU-3008-A Aluminum Electronics Minibox 7" L x 5" W x 3" H, Gray (x4); $22 USD, (x4) $88 USD
  • 2 × Non-Bonding Heat Transfer Compound Maximum Temperature 1562° F; .2oz; $12, (x2) $24; McMaster - 3715N11
  • 90 × Noninsulated High-Temperature Ring Terminals 1200°F Maximum Temperature, for 12-10 Gauge and Number 10 Screw; $13 USD (pack of 10), (x9) $117 USD; McMaster - 7113K31

View all 53 components

  • Selecting a Strip Heater

    Supplyframe DesignLab04/28/2022 at 18:11 0 comments

    Mica Insulated Strip Heater, Heater Voltage 120V AC, Overall Length 6 in, Mounting Dimension 5 3/8 in, Element Width 1 1/2 in, 100 W Watts, Watt Density 23W/sq in, Terminals Tandem at One End, Sheath Material Rust Resistant Coated Steel, 1 Phase, Max. Sheath Temp. 900 Degrees F, Slotted Hole Length 9/32 in, Slotted Hole Width 3/8 in, Screw Size 10-32, Standards UL Recognized

    There was a totally different concept for the internal support system of the frame.  It was initially going to use steel grid pattern, but we discovered that it would make the wiring near impossible to thread throughout the heating elements.  The Elements were also on a great sale at the time.

    https://www.zoro.com/tempco-ins-strip-heater-120v-6-in-l-900-deg-f-msh02260/i/G2033193/#specifications

    The first iteration of the BAD setup.

  • Creating the Brackets for Eboxes

    Supplyframe DesignLab04/28/2022 at 17:26 0 comments

    We wanted to mount the Eboxes to the frame in a way that would be relatively easy to mount and also remove... using hose clamps seemed to be a good option... so far so good!  The brackets did require a mill to machine the grooves for a well for the Press Frame and a little recess for the width and thickness of the hose clamp itself.

  • Frame Locks

    brucejdii04/27/2022 at 23:42 0 comments

    These are the fixtures that lock the Bolt together frame.  Unfortunately, there IS a mismatch along the front face.  You will put in the effort to mill or drill it already on a preexisting hole.

  • Working with PLA

    brucejdii04/27/2022 at 18:38 0 comments

    Knowing that we wanted to grind them up and reuse them- we've been holding onto discarded 3D prints for years!

  • Working with LDPE sheet material

    brucejdii04/27/2022 at 18:29 0 comments

    Here are some results using LDPE sheet and shredded material.

  • Working with HDPE pellets

    brucejdii04/27/2022 at 18:26 0 comments

    This is a test of HDPE pellets, which are meant for weighted blankets.  They melted great! Even and consistent, but difficult to pile up because the nature of them rolling around and getting everywhere.

  • Working with a Heavy Duty Paper Shredder

    brucejdii04/27/2022 at 18:19 0 comments

    We figured out that a heavy duty Paper Shredder, used for Credit Cards and CDs, also works great for plastics.  It isn't perfect, most bottles and materials need to be cut into smaller flat-ish pieces, or crushed into manageable sizes; material also needs to be run through the shredder about three times to get to a particulate consistency.

  • Wiring the Heating Elements - Setup & Testing

    brucejdii04/27/2022 at 18:11 0 comments

    A familiar face at the Lab, Emily Velasco, was available to help test the wiring and setup to the Solid State Relay, Temperature Controller,  and Rocker Switch.

  • Working with a Frame Mold

    brucejdii04/27/2022 at 17:49 0 comments

    I drilled and tapped a basic aluminum frame to make a small test mold. Two steel plates are being used as platens to avoid direct contact with the heating surface.  Wiping Silicone Oil on the surfaces of the plates was initially used, but Mold Release Spray was easier, more convenient and work better.

  • Power Plug + Wiring Crimping

    brucejdii03/17/2022 at 18:30 0 comments

    I ended up switching from regular terminal rings to high temp ends.

View all 16 project logs

  • 1
    Heat Press Setup Overview

    Shop Press Unbox and Assemble

    Cut and Bolt Heating Element Frames

    Ebox Layout, Fixturing, and Wiring

    Frame Molds for Plastic Cut and Bolt

    Material Shredding

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