How to Make Recycled BEAMS from Plastic Waste at Home

No this does not solve the entire waste plastic problem and no it does not really replace wood or steel beams in construction, as so many geniuses have pointed out in droves in these comments while missing the point entirely. But that is not the real point is it? The real point is that this is a creative and "outside the box" method for putting to use stuff we were going to just throw out entirely and let it sit unused in the landfills. Does it have to be used as a replacement or substitute beam for your deck or load bearing beam in your house? No, not at all and no one said that you must do that at all in the first place. But if you use your brain, anyone can see big potential for many other uses for this method if refined and improved. Could be useful for creating many other shapes for decorative coverings and finishes too, and not just limited to one use or application only. Wow there are so many - "I use a hammer for every problem I encounter" people out there. It is just a video showing creative humans using their brains and imaginations to try to make use of things that would be wasted and just tossed unused. However, now that throw away plastic will be put to use and less will go into the land fill. Why do most people state the obvious right off that bat? Of course not one simple idea will just solve a complex issue like our dependence on waste, but these folks never claimed that either. I say bravo and good thinking on trying something out in the first place. And by sharing their ideas it spurs others to think creatively (at least those of us who have the capacity to) to try to come up with alternatives as well.

You should strength test the plastic beam vs. A standard wooden one to see how it compares

Current price of lumber sure has me exploring some strange avenues.

Just a thought, maybe put a heating element under the aluminum with a manual nob or something to regulate the heat. That way you don't have to melt it outside the mold. Turn it on put all the plastic in the mold from the start (maybe half if the volume is to high) , apply some pressure with that fancy press :) and just let it melt into form.

I actually think this would be a great way to make sinks with a proper mold. 😊It’s a beautiful pattern and the sink would be almost indestructible. Also, outdoor table tops.

Toilet seats, toothbrush holders, vanity tops, tubs for mobile homes or tiny houses. You guys are awesome for this, I'd like to see you grow.

Here in Australia there is a company already producing these in a product called "Mod wood" to be used as an alternative, mainly used for flooring, decking & fencing. One thing they do to help with strength is use reinforced steel mesh in the guts of it. That may help you with your product.

I’ve read that using powdered almond shells can increase the repurposed plastics strength, it would be interesting to see the comparison between the two. I’m also curious if the rate at which the plastic cools effects it’s tensile strength. Awesome video guys

You need something like a crockpot to melt more and easier. Ideally, you are looking for something that can apply continuous, medium, and uniform heat over time. A pot solution would make it easier to add to the whole as the caps liquify. Also, the pot is ceramic which will hold the heat giving you more time to transfer the material to the mold.

Using a heat gun to control the heat while adding the plastic to the mold will lengthen the time to work with it. I also think if you used an old meat grinder (the kind that clamp to your dining table) to crush/shred the caps before melting will reduce air pockets as well as increase the number of caps per melt in the panini press.

You guys should do a stress test to see how it handles sheer and compression forces compared to a regular 2x4. I know the point isn’t finding an alternative to wood but it would be cool to see its failure point

You two are amazing if I would have had teachers like you when I was younger at school would have been awesome. Thank you for these videos I can appreciate your work very much.

Thank you for addressing process waste from cutting and sanding. It’s important to use what we’ve created but this is a vital detail.

In 1995, I went to a three-day recycling seminar where they had full-sized plastic dock pilings and said that they stayed strong through the pile driving process and held up in the weather.

If your mold is made entirely from heat conducting metal, perhaps the heating elements (whether from deconstructed appliances, or solar) could be added to the outside of the mold itself, to be used as a melting vessel as well as an end-mold. OR a long oven to contain the aluminum mold so that as one beam is cooling, another beam full of plastic can be put in to melt.

As I throw another bottle in the recycle bin I keep seeing products like this in my head. Thank-you for out of the box thinking. And trying to find useful solutions!

I love, absolutely love, people like your family. A family that plays together stays together. Wouldn't that be so cool if they could stop the pollution of all of its plastic bottle waste? Then make houses for the homeless made from plastic and old pallets, that people are just casting into the garbage, or on the side of the road. It's great to recycle!

Having learnt from you guys, I've now made a mould using 18mm ply and 2 plates of 6mm steel. Whilst I melt the bottle caps in one panini press, I heat the 2 steel sheets in another. Just before adding the plastic to the mould I insert 1 hot steel plate in the bottom. The melted plastic goes straight on top. I did use silicon sheets but by going straight on the steel it stops the minute brick pattern on the sheets pressing I to the plastic. Then I add the 2nd heated steel plate and then the 18mm wood. I use loads of F clamps. The result is that whilst it takes a little longer to cool, the heated steel plates makes the surfaces of the setting plastic absolutely flat with no air bubbles or wrinkles. This eliminates the need for a planer or thicknesses. I can change the thickness of the plastic slab by changing the 6mm steel plates for 4mm. Using a combination of these I can make 2mm to 14mm plastic plates, depending on what I want to make from them. So chuffed ive found you guys. You are awesome

I just discovered your channel and absolutely LOVE what you do! I am not a super DIYer, but I enjoy seeing this type of videos and getting inspired. I too feel......well, know, there is a LOT of plastic waste so anything that helps is worth looking into. Perorally, I will start looking at what can be done with this and action figures! 🙂 Keep up the good work!

I've created solar ovens using fresnel lenses salvaged from rear-projection televisions. Some of them were powerful enough to melt stone. I'd bet that you could make one that you could use to melt plastic and other recyclables without using so much electricity.