We from Circular Clockworks have designed a watch made from recycled materials to improve its image and to explain the circular economy.

Our development started with the extruder inspired by Dave Hakkens. Making some little changes to the basic framework to handle power better and to the fittings to make them suitable for general M-threading.

Our biggest challenge was to create parts with high tolerances and extremely thin wall thicknesses. The moulds we made for them were CNC-milled from aluminium at our University. The files needed for that, were quite easily generated by the moulding software of Solidworks. However with those moulds it was a process of trial and error to get some results. Gradually increasing the size of the injection nozzle, preheating the mould, and playing around with the plastic temperatures eventually led to filling up the mould completely. Getting the part out was the second problem. Redesigning the mould to be able to push the parts back out, was a must to salvage them in one piece.

At the end we managed to get parts out of the moulds, however only when all factors were perfectly managed. The current machine is not accurate enough to keep the conditions perfectly. Also the surface finish was never spot on. Surface treatment of the moulds itself could help to improve this. For us the injector was extremely helpful during the conceptualisation. For the production however it was just not cost effective.

With our project and our process we finally succeeded in finding the limits of hand-injection-moulding. If the machine would be just a little more accurate, it could definitely be a powerful prototype tool, where unlike 3d-printing not only form but also feasibility are put to the test. A great technique for every designer!
If you have become curious about our final watch, take a look at our website: http://www.circularclockworks.com