RecycleHub : a Mobile Workstation for Circular Makers

The goal of this project is to support plastic recycling in a more efficient, educational and sustainable way by developing a smart and compact workstation. The RecycleHub is designed for hands-on learning and functional clarity, made from durable materials that withstand daily use in schools, labs and creative spaces. Its heat-resistant surface allows for safe handling of hot molds and freshly formed objects, while integrated storage keeps tools and materials neatly organized and within reach.

Although the recycling process itself happens on separate machines, the RecycleHub plays an essential role in supporting every step of the workflow. With its mobility, any place becomes a workspace, from classrooms to maker events. It serves a wide range of users, from educators and students to makers and small-scale entrepreneurs. More than just a piece of furniture, it is a practical tool that brings order to creative work and invites more people into the world of circular making.

Here’s a list of the supplies needed to build one RecycleHub

Materials

1. Plywood sheets (2400x1200 mm) – 18 mm thick (for structure, drawers, and panels)
2. Stainless steel sheet – 1 mm thick, 764 x 432 mm (for the worktop surface)
3. Handle bar – Wooden or metal dowel, 24 mm diameter
4. Recycled plastic blocks – 30 mm thick (for custom components)
5. PETG filament – Made from recycled PET bottles (for 3D printed parts)
6. Wood screws – Diameter 3.5 to 4 mm
7. Caster wheels with brakes – 4 pieces, minimum 75 mm diameter

Optional parts

1. Drawer slides – 3 sets (dimensions depending on final drawer design)
2. Locking system for transport – Latches to keep drawers and bins secure during movement

Start by preparing your 18 mm plywood sheets for CNC cutting. Load the provided RecycleHub files into the CNC software and double-check all toolpaths for accuracy and material thickness. Secure the plywood firmly to the CNC bed to prevent shifting during the cut.

Run the CNC to cut out all required parts, including panels, sides, drawer fronts, back panels, and any recessed handle openings. Once the cutting is complete, label each piece clearly and sand the edges lightly to remove splinters or burn marks. Store the parts in order to keep assembly smooth and organized.

Cut all dxf files onces, except for "Side.dxf", "Board.dxf" and "BoardMid.dxf" these parts are needed twice.

Optional: you may skip the front files if you don't want drawers

Start by putting together the two horizontal shelves with the vertical divider. Align the pieces carefully so the edges match. Fix them together using screws only.

Next, take the assembled shelf unit and connect it to the back panel. Position it according to the layout, ensuring that the shelves are level and the divider is vertical.

Now, attach the top panel to the back panel

With the top, back and shelf assembly in place, it’s time to close the frame. Begin by positioning the two side panels against the structure. Make sure they align cleanly with the edges of the top panel, shelves and back. Fasten both side panels securely with screws.

Once the sides are attached, slide the bottom panel into position between them. Secure it with screws through the side and back panels.

Next up secure the back panel to the shelves and top panel with screws.This final step locks the entire corpus into a solid, box-like form and completes the main structure of the RecycleHub.

Turn the assembled corpus carefully on its back or side to access the underside. Position the four caster wheels near each corner of the bottom panel, leaving equal distance from the edges for balance and stability.

Mark and pre-drill the screw holes, then attach each wheel firmly using appropriate wood screws. Double-check that all wheels spin and rotate freely. Once secured, stand the RecycleHub upright.

Start by installing the drawer slides inside the corpus. Measure and mark the correct heights based on the drawer layout, ensuring they are level and evenly spaced. Secure the inner rails of the slides to the side panels using screws, making sure both sides align perfectly with each other to allow smooth movement.

Next, attach the outer parts of the slides to the sides of each drawer. Double-check that each pair is mounted at the same height and depth. Carefully slide each drawer into place, one by one, guiding the rails together until they lock in. Open and close each drawer to test the movement and adjust if needed for smooth, even operation.

Begin by adding the front panel to the open shelf. This panel acts as a barrier to keep bins or materials from sliding out during transport. Position it at the front of the shelf opening and hold it in place using a simple latch system, so it can easily be removed or opened when needed.

Next, install latches on each drawer to keep them securely closed while the RecycleHub is being moved. Mount the latches in a way that they are easy to operate but hold the drawers firmly shut during transport. Once installed, test all latches to ensure they lock and release smoothly. This step ensures that everything stays in place when the unit is on the move.

To finish the build, 3D print the corner protectors using recycled PETG filament. These parts are designed to shield the outer corners of the RecycleHub from impact during daily use and transport. Use the provided STL files and print with a high infill setting to ensure durability.

Once printed, align the protectors with the corners of the corpus. Secure them in place with screws through the pre-designed mounting holes. Make sure they sit flush and do not interfere with drawer operation or mobility.

To support the handlebar, you will need to create 3 sturdy holders that can be mounted to the side panels of the RecycleHub. There are two options for producing these parts, depending on your tools and materials:

Option 1: CNC from Recycled Plastic

Cut the handlebar holders from a block of 30 mm thick recycled plastic using a CNC router. Load the provided design file into your CNC software and carefully mill the parts, ensuring clean edges and a snug fit for the 24 mm diameter handlebar. Sand or deburr if needed.

Option 2: 3D Print with Recycled PETG

Alternatively, you can 3D print the holders using recycled PETG filament. Use the supplied STL file and a high infill setting for strength. Make sure the printed parts are solid and dimensionally accurate to support the handlebar securely.

Once created, mount the holders to the outer side panels at the appropriate height, and test fit the handlebar to ensure a firm and comfortable grip. With the holders in place, you can now install the handlebar on each side of the RecycleHub. The bars are positioned lower than standard handle height to improve ergonomics when lifting the unit into a van or transporting it over uneven surfaces.

Insert the 24 mm diameter handlebar into the holders and ensure it fits snugly. Secure the bar using screws or bolts through the predrilled holes in the holders. Make sure the bar is straight, firmly attached and comfortable to grip with both hands. Repeat the process on the opposite side.

This low-mounted handlebar makes it easier to lift the RecycleHub safely and reduces strain on the arms and back during transport.

Before the RecycleHub is ready for use, install the heat-resistant work surface. This top layer protects the workstation during tasks such as handling hot molds or freshly formed plastic parts.

Use a stainless steel sheet sized 764 by 432 mm. Position it carefully on the top panel so it sits flush and centered. Depending on your preference, fix it in place using screws in the corners, double-sided heat-resistant adhesive tape, or leave it removable for cleaning or replacement.

Once mounted, the stainless steel surface adds both durability and functionality, making the RecycleHub ready for intensive, hands-on recycling work.

With all components assembled and secured, your RecycleHub is ready for use. Move it into place, fill it with tools, molds and materials, and begin working in your Precious Plastic lab.

Whether you are hosting a workshop, developing new products or organizing your workspace, the RecycleHub is designed to support the daily process of plastic recycling. It offers a practical and reliable setup to help turn discarded plastic into valuable new creations.