ADDITIVE MANUFACTURING
0rCA is available as a 10% CF-filled PA in cut strand pellet form
0RCA EXPLAINED 0rCA is short for ‘near Zero (0) recycled CArbon’ and is more of a materials concept than a single product, Falconer says. He explains: “In 2019 we did a Life Cycle Assessment with Exeter University’s Environmental Sustainability Institute for our raw recyclate that returned a fantastic result. It showed that our recycling process could save 97-98% of the carbon emissions when compared to new nylon production.” The company has since bought its
own lab-scale compounding plant to advance the 0rCA project, allowing it to test and optimise new composite production in-house. The first commercially available
variant of 0rCA is a 10% CF-filled PA6 that can be bought as a cut strand pellet or as a 3D printer filament via the company’s global filament distribution partner, Fillamentum. According to Falconer, the material’s mechanical performance is equal to or better than most other PA-CF materials currently in the 3D printing filament segment. “It is relatively high temperature –
especially compared with PA11 and PA12 – impact resistant, chemically resistant and UV resistant,” he says. “As a materials family our CF10% variant has an estimated carbon saving of 90-95% versus virgin equivalents, so any company that currently uses PA6-CF but wants to slash their carbon impact for a
0rCA facilitates multi-component assemblies via injection moulding, FDM and SLS
particular product, 0rCA can be a drop-in replacement. In filament form, it is stronger than most virgin equivalents too.” Mono-materiality and co-
recyclability have been long-term drivers behind developing 0rCA as a family of materials. “The availability and usability of 0rCA across a range of manufacturing, not just additive, means that multi-component assemblies can be built using IM- built components as well as SLS and FDM made parts,” Falconer continues. “But at end-of-life, those assemblies do not need to be taken apart for recycling. This is a long-term consideration for designers when working towards compliance for the EU’s circular economy and product safety directives.”
TRUE SUSTAINABILITY CREDENTIALS Traceability is a key benefit for companies utilising 0rCA, Falconer adds. “Our base material is 100% recycled Nylon 6 and 100% of it comes from fishing vessels we know. We know where they fish, what species they fish for and their supply chain for the new nets. Few recycled materials have as good a provenance, and few new materials have as open a provenance.” 0rCA is designed for use across
multiple manufacturing methodologies, with a designer able to produce an early prototype using Fused Deposition Modelling (FDM), a low-volume
product using Selective Laser Sintering (SLS) and then mass production via injection moulding, all using the same material with the same supply chain. According to Falconer, high performance consumer facing items such as sports equipment, eyewear, and designer fashion are suitable applications for 0rCA, alongside low volume engineering componentry for spares and repairs, vehicle customisation and tooling. The powder has also been designed
to be accepted straight back into Fishy Filaments’ plant as a fractional source material for secondary use. “This work means we will offer 0rCA as a zero waste 3D printing powder for customers,” Falconer says. “Fundamentally, the recycled materials sector needs to be more understanding of what designers need rather than trying to get them to fit to what its own technical ability is right now. Recycling needs to be more ambitious about creating value and less about waste management.” Fishy Filaments is currently in
scale-up production with Warsaw- based Alpha Powders for 0rCA, and hopes to amass a group of technically competent early adopters to spur on the powder’s development and commercialisation.
For more information visit:
www.fishyfilaments.com
www.engineerlive.com 15
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