THE FANTASTIC PLASTIC TILE

Intro: THE FANTASTIC PLASTIC TILE

Recycling has become a bigger and bigger thing over the years and will be of even greater influence in the future. Not only are we trying to clean up the oceans, but this left over plastic needs a place to go. Where the current philosophy is that the separation of the household garbage happens at home and the recycling is being done by someone else, the shift is going to where the household can do the recycling themselves and create household or useful items from left over plastic at home.

This instructable is made for the TUDelft university course; TFCD

STEP 1: Collect

First of all you need plastics.

If you want to make a product from recycled plastics, make sure you save all your plastic bottles, caps, buckets and more. Instead of throwing it away, make sure to keep it all together.

There are many different types of plastics, which all melt on a different temperature. The best is to use plastics from the same melting temperature.

The plastic which could be used best for the plastic tile is HDPE, this is worldwide one of the most used plastics and easy to find. Next to this it is strong, though, easy to melt, and non-toxic.

STEP 2: Washing

It is very important to clean the plastic before use. When there are still solvents attached to the plastic, these solvents and impurities will cause problems in the melting by creating excess smoke and will prevent the plastic from sticking to each other.

STEP 3: Cutting

After collecting all the leftover plastic, the next step is to cut it all into small pieces. Small pieces will melt easier and it helps with being able to get all the plastic into the the right shape before melting.

Cutting could be done by hand or you could use a shredder or an food processor. To cut the plastics into smaller pieces.

STEP 4: Draw Shape

We are now making a tile for in the street which will replace an existing stone tile. Because of this we are using a 30x30 cm mold. The thickness will be 4 cm. The best is to create a side wall a bit higher than the thickness you want to be sure the plastic does not go over the edge.

Draw the shape on paper and calculate the right messurements.

STEP 5: Cut Material

Cut the material, in this case aluminium in the right shape.

For the tile we used a 40x40cm sheet and took out small squares in the corners form 5x5cm. After you cut out the squares you can bend the sides to create a box.

STEP 6: Cut Out the Top

After melting the plastic needs to be pressed into the mold and therefore you need a top, on which you can add pressure. Cut out a 30x30 cm top.

STEP 7: Fix the Mold

In this case we welded the mold together on the edges.

Note; if the material you use is stiff enough, and there is no big gap between the edges you can leave it open.

STEP 8: Heat Up the Oven

Heat up the oven till 200C degrees.

STEP 9: Add Baking Paper

The melted plastic could stick to the mold if you put in the plastic directly, so put in baking paper to keep it from sticking, just like baking a cake ;) .

STEP 10: Put in the Plastic

Take al the clean, dry and cut up plastic pieces and put them in the mold in the way you want it is your imagination that will eventually decide the outcome of the colors.

STEP 11: Let It Melt in the Oven

Place the mold with the HDPE pieces in the oven. Make sure the oven does not exceed the 200C degrees, as you could burn the plastic. Now you wait, until the plastic becomes shiny

STEP 12: Take It Out

After about 90/120 minutes, Depending on the thickness of your tile, take the mold out of the oven. When the plastic is melted and shiney it is ready!

STEP 13: Pressure

Use the top, and place this on top of the melted plastic and press it down firmly. You can also use klamps to push the top down, and make sure the HDPE is pressed into the corners.

STEP 14: Demold

When cooled down, take the tile from the mold. This could be done by turning it over. When you use baking paper this shouldn't be a problem!

STEP 15: Finish

To nicely finish the tile you can use an iron or a heat gun at the end to quickly heat up sticking out elements, and press them into shape. (be careful to not burn it!)

STEP 16: Ready!

The tile is ready to use! take an old tile and replace it with your new recycled HDPE tile!

Comments

[Teamjulie]

Could I use a baking pan or cake pan as the mold?

[palangejohanne]

How can you be sure the tiles are all going to have the same thickness? Do we weigh the amount of plastic we will be using to get the same amount in each tile?

[education2214]

Thank you so much for a nice innovation! Please, how can we handle the issue of toxic pollution while burning the plastic? Help with suggestion please! Thanks

[hemanthkumarmh.hkmh]

I and my friend are doing this project because of you we are implementing it. thank you

[TedB33]

I am trying it to. I find it's one thing to read or view a video. It's another story to try it, but I think I got the hang of it now.

[agbaigwe0]

Does it burn? That is in a case of fire outbreak. Is there a way we can overcome that if it does?

[TedB33]

I tried this recently in my tiny electric grill with a heater on top and bottom. the parchment paper touched the top grill and sent smoke out. Plastic may give off an invisible gas at 400 F or so, but haven't have burning problems. I melt in a ventilated area.

[prebastian31]

We get this procedure for our thesis , and hoping to be succesful. Thank you so much😊

[lhgrappler]

Awesome. Wish I could find a way to make a form for a seat bottom and curved back. Any ideas?

[The_Girl_Next_Door]

Can it be melted longer so it does not look like confetti? I would also like to use this on the floor. Is there a way to make it so it is not slippery? Also how thick does it need to be to be durable?

[chunkysteveo]

After looking around at all the HDPE recycling posts, videos, blogs etc - I found this one very useful. However, i've noticed that a lot of people say how slippy and "non-rough" HDPE can be once moulded. I am wanting to create a recycled floor for my garage workshop using some form of HDPE tile solution, but won't it be a dangerous surface to walk on/work on?

[Norfolkson]

I applaud your innovative recycling. Well done sir! However I have two concerns, ....1) Heating plastic releases toxins into the atmosphere and therefore is a pollutant that cannot be reclaimed and 2) Since all plastic is toxic in any form no matter how it is processed or re-processed, it is my view that ALL plastics should be removed from our environment in their entirety, rather than be re-used in any way whatsoever. Nevertheless, your mindset is in the right direction to help our planetary environment!

[Jethrokill]

Sorry Norfolkson, but you should do your research and know the facts before you post a critical comment. Especially since this method of plastic processing is widely known. I don't know if you were just attempting to troll, but the fact is that HDPE and many other plastics are "thermoplastics" and can be reheated/melted (below their combustion temperatures) many times and do not release any "toxins".

[mdowling3]

https://preciousplastic.com

[Swansong]

That's a neat way to add a pop of color! :)