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I met Sidhant Pai at the 2014 3D PrintShow where he was displaying Protoprint’s 3D Printer filament made from waste-picked recycled HDPE. After the show, we discussed Protoprint’s social enterprise, company origins and the machines used to create their fair-trade 3D printer filament.  – Anna Kaziunas France

Protoprint_Waste_Sorting

Indian Waste Pickers sorting plastic.

What is Protoprint?

The FlakerBot

The FlakerBot

Protoprint is a social enterprise based in India that empowers urban waste pickers with the technology to convert waste plastic into 3D printer filament. The organization markets the filament globally as a price-competitive, fair-trade alternative to virgin filament while simultaneously using it locally to provide affordable 3D-printing services to students and professionals in India.

Over 12.5 million tons of plastic is consumed annually by India and almost all the segregation of the plastic occurs at the dump site, where waste pickers sift through garbage, separating the plastics from organic waste. They sell the plastic to middlemen scrap dealers but receive an extremely low amount for their important work. After spending the day trawling through trash, many of these hardworking individuals earn less than $1/day and live in impoverished conditions.

What inspired you to start a social enterprise company?

Growing up in Pune, I had a great childhood but was exposed to a lot of problems common to a developing-world environment. When I came to MIT, I was interested in the use of low-cost technology for development and worked on projects in Tanazania and Nicaragua during my first two years (Pedal Powered Butter Churn in Tanzania, Affordable Solar Cell Phone Charger in Nicaragua).

The RefilBot

The RefilBot

During my sophomore summer, I was looking into grassroots recycling technology to move waste pickers higher up the value chain. At the same time, my father was playing around with the idea of building a 3D printer. As we were talking one day, it struck us that the filament used by FDM printers was fairly simple to extrude. We started looking into designing low-cost extrusion machines.

How was the company formed?

Over the spring semester of the following year, I mentioned the idea to Katie Spies (an MIT classmate). She was immediately interested and joined the team. The MIT Team (Katie and I) worked in collaboration with the India team (my parents) to design and develop the ‘FlakerBot’ and ‘RefilBot’.

While we iterated on our technology, we began building a relationship with SWaCH (the waste pickers co-operative) in Pune. Last summer, we set up our pilot ‘Filament Lab’ at a dump site and began working with them on processing the waste HDPE.

Tell me more about the machines that turn waste HDPE into 3D-printer filament

The Flakerbot is a compact machine that uses a rotating 5HP shredder to ‘flake’ the HDPE bottles we put through it. The RefilBot is a compact extruding mechanism that uses a rotating screw conveyor to transport the flakes through a ‘cooking’ process that melts it before extruding it to 3mm filament. Our machines are designed to be low-cost, safe, and easy-to-use in order to better integrate with the waste pickers current supply chain.

recycle Wealth from Waste: Protoprints Fair Trade 3D Printer Filament

We’re still in the process of improving the RefilBot to increase the rate of extrusion. Once completed, we’re looking at making both the process and plans available freely to others looking to adopt a similar model. Currently, we’re not looking to sell them but it may be in the cards down the line.

Tell me more about how Protoprint works with waste pickers

Protoprint’s technology enables waste pickers to convert the HDPE plastic they collect into 3D printer filament. By working collaboratively with waste picker co-operatives in India, Protoprint sets up filament production facilities at dump sites and trains the waste pickers to use the technology, enabling them to create 3D printer filament from the plastic they collect and transforming them into micro-entrepreneurs. This allows them to earn over 15 times more for the same amount of plastic, empowering them both socially and financially.

Komal processing a bottle at our pilot shed in Pune.

Komal processing a bottle at our pilot shed in Pune.

Protoprint currently has a pilot ‘Filament Lab’ set up in the city of Pune (India) where we’ve partnered with a local waste picker co-operative called SWaCH. Komal, the daughter of a waste picker herself, oversees the filament production and sources the HDPE plastic from a network of local waste pickers.

What’s next for Protoprint?

Our filament is currently produced in 5 different colors and Protoprint is using the pilot period over the next 6 months to test the filament on a number of commercial printers. We are looking at making the filament commercially available starting mid-2014 in both 3mm and 1.75mm variations.

Wealth from waste has been the waste picker motto for decades, and the team at Protoprint embraces it whole heartedly.

Anna Kaziunas France

Digital Fabrication Editor of Maker Media.

She runs the digital fabrication hardware testing for Make:. If you’re a vendor who would like to submit a tool for review (3D printer, CNC, laser cutter, fab software etc.), contact her directly at: anna [@] makermedia [dot] com.

She’s the section editor for Make: Skill Builder. Make: celebrates your right to tweak, hack, and bend any technology to your will. But — In order to really tweak and bend something, you need to understand it! If you’d like to write a tightly focused piece on a core maker skill in science / engineering / craft / art / architecture / robotics / fabrication etc. (whatever) that you’d like to teach to other makers — and have Make: work with you to illustrate for magazine publication — let her know!

She’s very interested in your ideas for practical digital fabrication focused books — anything that turns codes into things — hardware and software.

She’s also the Dean of the global Fab Academy program, the co-author of Getting Started with MakerBot, compiled the Make: 3D Printing book and ran the 2015 and 2014 3D Printer Shootout Weekend testing events.

She likes things that are computer-controlled, parametric, and open source — preferably all three.

Find her on her personal site, Twitter, , and Facebook.


Sidhant Pai

Sidhant Pai

Sidhant is the CEO of Protoprint and a fourth year engineering student at the Massachusetts Institute of Technology. Born and raised in India, his interests are in international development and low-cost technology. Prior to his venture into 3D printing, he has worked on grass-roots projects in Nicaragua and Tanzania. In addition to his interest in development, his academic interests involve urban air quality and atmospheric pollutant transport.


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