Using Open Source Compression Molding and Vacuum Forming to Incentivize Localized Recycling: An Integrated Thermoforming Solution

This work aims to make thermoforming more accessible to incentivize prosumer participation in localized recycling by providing a combined open source 12” x 12” compression molding and vacuum forming tool. The hardware was validated across a series of applications, each providing a different economic or functional incentive. For prosumers, this included compression forming 1/4" recycled polycarbonate and HDPE sheets, 20-gauge vacuum sheets, and vacuum formed applications with savings of up to 99.9% over commercial sources for 100-part batch production case studies. For researchers and commercial interest, the hardware was used to produce ASTM D695 standard samples of 1:1 silica sand and polycarbonate. The resulting composite was mechanically tested to yield a 71MPa average compressive strength competitive with high performance concrete. The hardware presented in this study provides users with the resources to manage local recycling for product development, customization and research using traditional thermoforming methods in a reduced footprint.