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DIY Recycled Panel From Polyester Textile Waste + Plastic Waste

DIY Recycled Panel From Polyester Textile Waste + Plastic Waste

This guide shows how to shred polyester textile waste, mix it with shredded plastic waste, and heat press it into a solid recycled panel.

This works best when the plastic waste melts and acts like glue, while the polyester textile adds strength and structure.

Tools and Materials

 

Tools

  • WasteFree23-style heat press with temperature control and flat plates
  • Shredder or strong scissors and cutters
  • Weighing scale
  • Mixing bucket or large container
  • Heat resistant gloves
  • Fan or good ventilation

Materials

  • Polyester textile waste (best if 100 percent polyester)
  • Plastic waste (PP, HDPE, or LDPE)
  • Non-stick sheets such as Teflon sheet or baking paper

Step 1: Sort and Identify Your Materials (Keep It Simple)

A) Sort Textile Waste (Find Polyester)

Best method: Read the clothing label

  • KEEP: “100% Polyester” or “Polyester 90%+”

  • MAYBE: Polyester + cotton/viscose/nylon

  • REJECT (or use very little): Elastane/Spandex/Lycra, PU foam, wool, silk

No label? Do 2 quick tests

  1. Water drop test

  • Water stays on top = likely polyester (KEEP)

  • Water absorbs fast = likely cotton (REJECT)

  1. Stretch test

  • Very stretchy and snaps back hard = elastane blend (REJECT)

Also remove: zippers, buttons, metal parts, thick elastic.

B) Sort Plastic Waste (Choose One Type)

Best method: Check recycling code

  • KEEP:

    • #5 PP (best)

    • #2 HDPE

    • #4 LDPE

  • REJECT:

    • #3 PVC (dangerous fumes)

    • #6 PS (brittle)

    • unknown plastics

No code? Do 2 quick tests

  1. Float test (bucket of water)

  • Floats = usually PP/PE (KEEP)

  • Sinks = PET/PVC/unknown (REJECT)

  1. Bend test

  • Bends without cracking = PP/PE (KEEP)

  • Cracks easily = reject

Goal at the End

You should have:

  • Polyester textile pile (clean and dry)

  • One plastic pile only (PP or HDPE or LDPE)

Best beginner combo: Polyester + PP (#5)

Step 2: Dry Everything Completely

Moisture is a major cause of bubbles and weak panels.

  1. Sun dry your textile and plastic for several hours.

  2. If possible, dry indoors overnight to remove leftover moisture.

  3. Store dry material in a sealed bag or container until pressing.

Step 3: Shred the Polyester Textile Waste

Goal: Increase surface area and make it pack evenly.

  1. Cut polyester fabric into small strips.

  2. Target size: 10 to 30 mm long strips.

  3. Try to keep thickness consistent.

Tips:

  • If pieces are too large, the panel becomes uneven.

  • If pieces are too fine, it can clump and reduce strength.

Step 4: Shred the Plastic Waste

Goal: Smaller plastic pieces melt faster and spread better.

  1. Cut plastic into flakes or chips.

  2. Target size: 5 to 15 mm pieces.

  3. Keep similar plastics together for consistent melting.

Step 5: Choose Your Mixing Ratio

A strong starting recipe is:

  • 60 percent shredded plastic waste

  • 40 percent shredded polyester textile waste

Example:

  • 600 g plastic

  • 400 g polyester textile

If your panel breaks easily, increase plastic content.
If your panel is too soft, increase polyester content.

Step 6: Mix the Materials

  1. Put the weighed plastic and polyester into a bucket.

  2. Mix by hand until the polyester looks evenly distributed.

  3. Do not leave large clumps of fabric in one area.

Step 7: Prepare the Heat Press

  1. Place the heat press in a well-ventilated area.

  2. Preheat the press.

Suggested temperature ranges:

  • PP binder plastic: 175 to 190 C

  • HDPE binder plastic: 150 to 170 C

  • LDPE binder plastic: 130 to 150 C

  1. Place a non-stick sheet on the bottom plate.

  2. Prepare a simple frame mold if you want a controlled thickness.

WasteFree23 recommends non-stick sheets and a simple low-cost heat press design.

Step 8: Load the Material Into the Press

  1. Spread the mixed material evenly inside the mold area.

  2. Try to make the thickness uniform.

  3. Place another non-stick sheet on top.

Optional:

  • Put a flat metal plate above and below the material to improve flatness.

Step 9: Heat Press the Panel (Two-Stage Method)

This method reduces bubbles and improves bonding.

Stage 1: Melt and flow stage

  1. Close the press gently.

  2. Apply low to medium pressure.

  3. Hold for 4 to 7 minutes.

Purpose:

  • Plastic starts melting and spreading into the polyester.

Stage 2: Full compression stage

  1. Increase pressure.

  2. Hold for 5 to 10 minutes.

Purpose:

  • Removes air pockets

  • Densifies the panel

  • Improves strength

Total pressing time is usually 8 to 15 minutes depending on thickness and plastic type.

Step 10: Cool Under Pressure

This step prevents warping and layer separation.

  1. Turn off the heat or reduce temperature.

  2. Keep the press closed.

  3. Let it cool for 5 to 15 minutes.

Do not open the press too early.

Step 11: Remove and Finish the Panel

  1. Open the press carefully using gloves.

  2. Remove the panel and peel off the non-stick sheets.

  3. Trim the edges with a knife, saw, or grinder.

Optional finishing:

  • Sand the surface

  • Drill holes for mounting

  • Cut into tiles or strips

Step 12: Quick Quality Checks

Check 1: Bend test

Try bending the panel slightly.

  • Good panel: bends slightly without cracking

  • Bad panel: cracks quickly

Check 2: Delamination test

Try pulling apart the surface layers.

  • If it peels easily, it needs more heat, more pressure, or more plastic binder

Check 3: Bubble inspection

Look for holes and bubbles.

  • Many bubbles usually means moisture or trapped air

Troubleshooting Guide

Problem: Panel is weak or crumbly

Fix:

  • Increase plastic ratio to 70 percent plastic and 30 percent polyester

  • Increase pressing temperature by 5 to 10 C

  • Increase pressing time by 2 to 5 minutes

Problem: Panel has many bubbles or holes

Fix:

  • Dry materials longer

  • Use the two-stage pressing method

  • Pre-press lightly for 30 seconds before heating

Problem: Panel is warped

Fix:

  • Cool longer under pressure

  • Use flat metal plates above and below the material

Problem: Burning smell or smoke

Fix:

  • Reduce temperature

  • Stop and check for wrong plastics like PVC

  • Remove elastane-heavy fabrics

Safety Notes (Important)

  • Always work with ventilation or outdoors

  • Wear gloves and eye protection

  • Avoid PVC and unknown plastics

  • Keep a fire extinguisher nearby