ReForm - Requirements

VGU Challenge

Customer requirements

What is at stake?

Project background

EGL counts on GPEM to construct the prototype that was announced to MBI. Thus, we can rely on their engagement to finance the prototype to the extent of the material costs.
EGL would like to focus mainly on the heat forming > How to melt and go from melted plastic into a shape with different technologies. However students should understand and consider up- and downstream manufacturing steps to ensure that the machine can be integrated with the elements sourced by EGL.
Students results include: Machine manufacturing plan, material list, pricing/ sourcing, estimated time for construction; machine to be constructed by faculty together with students for most suitable solution presented to judging panel.
A clear vision of the different possible outcomes should be defined for the realization of a prototype directly after the course by VGU Precision Manufacturing Laboratory. Our wish is to integrate innovative results of students’ design. Minimum output: make an already working blueprint from defined open source, with proven model
We encourage students to focus on specific contributions identified by EGL, as they have a good overview of this project. Challenge:
- Strategy 1: Repurpose existing machines not currently used for plastic processing and tailor toward plastic processing / improved properties for the plastics case
- Strategy 2: Implement and if possible improve an already existing blueprint for a plastic processing machine
Don’t focus on the shredder because we are not sure to reach the quality of shredded plastic and it is not the biggest challenge in the value creation.
Machines that can be integrated, already bought by EGL: a shredder worth 700USD, a t-shirt heat press heating up to 400°C but only from one side, and a 10 tons hydraulic press.
EGL already have built a prototype made of repurposed machines where the output of one 30x30cm tile after 7-10mn manual processing. This output is currently not satisfactory and further issues were identified when testing the prototype.

Customer requirements

Technical customer requirements

Input of the machine: Plastics type PP and PE (optional: PS and PC), electricity: 220V
Output of the machine: Continuous plastic sheets or 300x300 plastic sheets. Required thickness: 5-9mm. Bent and air-filled sheets are not allowed.
Capacity: 5kg/hour and working continously 16 hours
Lifespan: 5 years
Total machine weight: <100kg
Energy and operation cost have to be calculated and clearly stated
Maintenance plan: no components make up more than 25% of total material cost.
Safety of operators and maintenance staff has to be insured at all levels. For moving parts, safety mechanisms have to be considered (e.g. kill switch, etc.)

Final solution, sourcing and pricing

The Heat-Forming machine fits in a social franchise with (1) machines including washing mechanism, shredder, melting and forming elements (2) a training for the staff to use the machine, (3) a maintenance plan and (4) a profit for the franchise operator and for the machine manufacturer.
Breakdown of cost as follows: 5000 USD per center; 50% Machinery, 50% Equipment and training; 2500 USD for full processing line: 700 USD for Shredder and 150 USD for cleaning station, 150 USD for ventilation (if required - buffer) and 300 USD for transportation, 1200 USD for heat forming solution is approximate price for serial production.
Material of prototype should not be more expensive than the budget figures below.
Only local material and suppliers are allowed, no imports.

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