The world’s first microfactory that can transform the components from electronic waste (e-waste) items such as discarded smart phones and laptops into valuable materials for reuse has been launched at the University of New South Wales (UNSW) in Sydney.

Using technology developed following extensive scientific research at UNSW’s Centre for Sustainable Materials Research and Technology (SMaRT Centre), the e-waste microfactory has the potential to reduce the rapidly growing problem of vast amounts of electronic waste causing environmental harm and going into landfill.

According to SMaRT Centre Director, Professor Veena Sahajwalla, the e-waste microfactory will be the first of a series of microfactories under development and in testing at UNSW that can also turn many types of consumer waste streams such as glass, plastic and timber into commercial materials and products. For instance, from e-waste, computer circuit boards can be transformed into valuable metal alloys such as copper and tin, while glass and plastic from e-devices can be converted into micromaterials used in industrial grade ceramics and plastic filaments for 3D printing.

“Our e-waste microfactory and another under development for other consumer waste types offer a cost-effective solution to one of the greatest environmental challenges of our age, while delivering new job opportunities to our cities but importantly to our rural and regional areas, too,” says Sahajwalla. “Using our green manufacturing technologies, these microfactories can transform waste where it is stockpiled and created, enabling local businesses and communities to not only tackle local waste problems but to develop a commercial opportunity from the valuable materials that are created.”

Sahajwalla believes microfactories present a solution to burning and burying waste items that contain materials that can be transformed into value-added substances and products to meet existing and new industry and consumer demands. They offer a truly sustainable solution to our growing waste problem, while offering economic benefits to local communities.

“We have proven you can transform just about anything at the micro-level and transform waste streams into value-added products,” she says. “For example, instead of looking at plastics as just a nuisance, we’ve shown scientifically that you can generate materials from that waste stream to create smart filaments for 3D printing.

“These microfactories can transform the manufacturing landscape, especially in remote locations where typically the logistics of having waste transported or processed are prohibitively expensive. This is especially beneficial for the island markets and the remote and regional regions of the country.”

UNSW has developed the technology with support from the Australian Research Council and is now in partnership with a number of businesses and organisations including e-waste recycler TES, mining manufacturer Moly-Cop, and Dresden, which makes spectacles. During the launch of the micro-factory in April, NSW Minister for the Environment Gabrielle Upton said it was exciting to see new technological innovations that could transform waste management and recycling.

“I am very pleased to launch the UNSW e-waste microfactory, a NSW home-grown solution to the waste challenges facing communities all over the world,” said Upton. “It is exciting to see innovations such as this prototype microfactory and the potential they have to reduce waste and provide a boost to both the waste management and manufacturing industries in NSW.”

How it works

UNSW’s modular micro factories can operate on a site as small as 50sqm and can be located wherever waste may be stockpiled. A microfactory is one or a series of small machines and devices that uses patented technology to perform one or more functions in the reforming of waste products into new and usable resources.

The SMaRT Centre e-waste microfactory has a number of small modules for this process and fits into a small site. Discarded devices such as computers, mobile phones and printers are first placed into a module to break them down. The next module may involve a special robot for the identification of useful parts. Another module then involves using a small furnace, which transforms these parts into valuable materials by using a precisely controlled temperature process developed via extensive research.

The materials transformed include metal alloys and a range of micromaterials. The micromaterials can be used in industrial-grade ceramics, while the specific quality plastics from computers, printers and other discarded sources can be put through another module that produces filaments suitable for 3D-printing applications, and the metal alloys can be used as metal components for new or existing manufacturing processes.

While the SMaRT Centre is expanding its partnerships with industry, investors and local councils, the challenge is to commercialise and create incentives for industry to take up this technology – and to change behaviour – as societies and communities around the world seek to become more sustainable.

www.smart.unsw.edu.au