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I've successfully fused mixed contaminated plastic

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This topic contains 13 replies, has 10 voices, and was last updated by  Wolfgang Koelblinger 4 weeks ago.

Khalid khalidkhames

I've successfully fused mixed contaminated plastic

10/01/2018 at 14:14

Hello Precious Plastic people!

My name is Khalid and I reside just outside of Edinburgh, Scotland, in the United Kingdom.

I began investigating the issue of plastic waste whilst trying to reduce my company’s recycling costs.

After many trials and research I’ve been able to fuse together dirty, mixed contaminated plastics into usable blocks.

I’ll shortly be crowd funding to commercialise this, giving away (FOR FREE) the lengths of extruded material as alternatives to precious timber or metal, reducing our environmental impact whilst diverting waste away from landfill.

The fused material is very strong and with a little colouring should turn into really solid black lengths, perfect for making outdoor furniture, fence posts, support beams and more.

I’ve uploaded an image showing what I’ve done so far.

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10/01/2018 at 23:59

wow nicely done!
It would be interesting to know more about it!
Do you use precious plastics machines?
When you say “contaminated”, with what is it contaminated?
And what kinds of plastics do you mix?
Thanks for sharing!!

11/01/2018 at 06:21

Just wondering when you fused the plastics together have you tested for toxicity. i would be very interested in what you find out.

11/01/2018 at 12:08


No I did it on a small scale using my own equipment, nothing fancy.

I mixed everything I could find;

– Cotton swabs
– Bottles
– Films
– Toothbrushes
– Packaging

The material was contaminated as it contained various non-plastic elements. For example the toothbrushes had toothpaste on them, the packaging food and the bottles liquid.

11/01/2018 at 13:43

Have you done any tests on the resulting material, such as measuring it’s tensile strength? This would be useful if you want to propose it as an alternative to eg. timber or metal.

12/01/2018 at 13:10


Not yet, but I can tell you its bloody strong!

It cuts with a hacksaw and takes some doing! I’ve drilled into it and hit it with a hammer.

18/01/2018 at 22:09

I can definitely see the appeal, but i would say that the use would be limited to non structural applications, as there would be a quite a large difference in how it behaves from batch to canh, simply due to the fact that the exact makeup of the end material would vary quite a lot, and due to the fact that it is rather contaminated by dirt, degraded plastic and so on.
Not trying to shoot down the idea at all, i’m just hoping to add something to the conversation:)

01/02/2018 at 08:01

Hi Kalhid, Fantastic technological innovation! Will you be making the process and fusing instructions open source ?

01/02/2018 at 10:42

Well remember to clean your plastic!
Even companies who also mixes plastics are washing their materials, as you newer know the toxidity dangers of what is being mixed.
This will also affect your outcome, as @clementhempel also says.
Try only to mix your material if you have to. Like when recykling products that is made of parts from different types of plastic, BUT SORT THE PLASTIC WHEN YOU CAN!
The plastic you are fusing can not be recykled again easily, and you will not help the envioment that much.

Please do alot of research before going on with this

Good luck


06/08/2018 at 01:16

@khalidkhames Great work! Do you have any updates on your progress with this? Are you able to share any details on what sort of process you use?

24/08/2018 at 18:22

Hey there @khalidkhames
Just so i understand the topic correctly; the photo shows part 1 & 2 complete and 3rd image would be through crowdfunding ?

If so i am sorry to say that i am kinda sceptical on your process. How could random “plastics & other materials/liquids” just be put together in big temperature and obtain a new “material”, which would be… totally random depending on what has been put together?

I really don’t want to be mean in any way, but please think your process through or maybe explain more ? because i have a lot of difficulties understanding the logic of this

24/08/2018 at 20:15

Hi all,

I’m really sorry for the delay in replying!


I spent a lot of my own personal money promoting my idea and attempting to CrowdFund a commercial scale process but unfortunately it didn’t work.

I have had many positive and negative comments regarding what I done and ultimately my aim was to try to take trash and turn it into something usable without any complicated or costly processes involved. Regardless of the material type, cleanliness or prior usage I wanted to be able to accept anything and turn it into something useful.

I conducted no trials as to the strength or usablility of the product other than to play around with it myself. It could easily be sanded or cut and my idea was to create bar lengths that could be used to create furniture like tables and chairs. When those items became damaged or old they could be recycled again to create more raw material for manufacturing.

Despite my failures I learned a lot and I’m pleased there’s actually a viable company doing something even better than what I attempted. UK company Recyling Technologies takes waste plastic and heats it to its melting point to create an oil that is resold back to manufacturers. My hope is that this will turn global and we’ll reverse the damage we have done to the World.

25/08/2018 at 05:53

hi khalid … how do you extrude fused plastic … any videos ?

25/08/2018 at 06:49

hi kahlid .. i just read your inbox .. I’m not an expert on plastic but i used to teach chemistry … you should sort plastic into some main categories …

…. long  carbohydrogen chains like ldpe,hdpe and even pp shredder … not above 200 Celsius  and not containing circular structures like like ps
once you have more experience, sort out also pp ..

… carbohydrogen structure that contain rings like ps and heat them as hot as around 230 celcius… don’t mix them with pe or pp  as they won’t connect

… don’t add  pvc or  other compounds containing chlorine … reaction could create dioxines and other kinds of poison ..

if you make sticks and boards it’s alright to have contamination in them as compact material doesn’t enter the food chain or damage animals … decades later people may bury it somehow without  any harm in concrete walls etc.
… go on in your search and try no to breathe gases … i hope this is useful for you … wolfi

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