Patent Publication Number: US-10759089-B1

Title: Recycling materials in various environments including reduced gravity environments

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation of U.S. application Ser. No. 14/604,743 filed Jan. 25, 2015, which claims the benefit of U.S. Provisional No. 61/931,568 filed Jan. 25, 2014, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to recycling materials, and more particularly to apparatus, systems and methods for creating recycled feedstock for additive manufacturing devices. 
     BACKGROUND 
     Delivery of materials to space is an expensive and time-consuming undertaking and materials are rarely reused. Currently, launch costs per kilogram to low Earth orbit (LEO) are well over $1,000 per kilogram. As of 2013, estimated cost per kilogram of the Atlas V® vehicle (available from United Launch Alliance, LLC of Centennial, Colo.) is $13,000. The Falcon 9 v. 1.1 vehicle (available from Space Exploration Technologies, Inc. of Hawthorne, Calif.) delivers payloads to LEO for $4,000 per kilogram. At such prices, even the simplest items, such as a wrench, screw driver, or a clip, have total costs measured in the hundreds or thousands of dollars. 
     Additional barriers currently exist for rapid delivery of goods and materials to manned and unmanned spacecraft because launches are also infrequent, booked many years in advance and often significantly delayed. Even frequent destinations such as the International Space Station receive supplies infrequently. For example, six unmanned spacecraft delivered materials and fuel (also known as “up mass”) to the ISS in 2011. In 2012, resupply missions were carried out nine times. Space is limited on such resupply missions, delaying delivery of replacement parts. When replacement parts are sent to the ISS, they require up mass that could be used to send additional supplies, equipment and scientific experiments to the ISS. 
     Exemplary resupply missions to the ISS utilize unmanned spacecraft, such as the Dragon capsule (available from Space Exploration Technologies, Inc. of Hawthorne, Calif.), the Russian Progress freighter spacecraft, or the Cygnus vehicle (available from Orbital Sciences Corporation of Dulles, Va.). The resupply spacecraft is launched into orbit carrying supplies including new equipment, replacement parts, fuel, oxidizer, food, water and scientific experiments. The spacecraft docks with the ISS and is unloaded. The spacecraft is then reloaded. If the spacecraft is capable of being returning to Earth and being recovered (e.g., the Dragon capsule), it is loaded with science experiments, old station hardware, equipment, and trash. The spacecraft is then launched, returning to Earth for recovery. If the spacecraft is not capable of being recovered, the spacecraft is typically loaded with trash and launched, where it burns up on reentry. 
     Trash management is problematic in isolated locations such as aboard a spacecraft, on naval vessels, and at remote outposts. In the ISS, all trash is stored on board in the habitable volume until it is disposed of as described above. Astronauts compress the trash by hand into stowage bags, but this can only reduce the volume by an estimated 50%. The present “store and return” method has limitations. For example, it will not meet the requirements for future human space exploration missions. Missions to deep space destinations such as the Moon, asteroids, Lagrange Points, and Mars will require different disposal methods. Ejecting trash into space, as practiced with liquid waste during the Apollo missions, is not practical or efficient for solid trash such as packing materials, broken equipment, and the like. With the possibility of resupply years between or nonexistent, astronauts must bring everything with them, meaning every piece of cargo is a precious resource. Furthermore, missions will need to safely manage waste and avoid polluting and contaminating other solar system bodies by, for example, abiding by NASA&#39;s Planetary Protection Policy (NASA NPD 8020.7. “Biological Contamination Control for Outbound and Inbound Planetary Spacecraft”). 
     Currently, recycling or repurposing materials in space presents several problems. Among traditional recycling processes do not function in the microgravity environment of space. Similarly, current recycling processes are not adapted for use in high acceleration and vibration environments such as those found aboard a naval vessel or submarine. 
     On Earth, naval vessels that are required to be at sea for extended amounts of time face similar logistical problems such as dealing with long periods of time between resupply events, a lack of recycling opportunities and inefficient waste management during voyages. Research stations located in remote locations such as Antarctica require similar logistical challenges. 
     Given the foregoing, apparatus, systems and methods are needed which facilitate recycling of trash aboard spacecraft, space habitats, and the like. Additionally, apparatus, systems and methods are needed which facilitate reducing mass and volume devoted to trash storage and transportation. 
     Additionally, what is needed are apparatus, systems and methods which reduce trash volume and mass and facilitate recycling of trash during long duration explorations, at remote outposts, and aboard naval vessels. 
     Additionally, what is needed are apparatus, systems and methods which facilitate processing in-situ resources into a usable form. 
     SUMMARY 
     This Summary is provided to introduce a selection of concepts. These concepts are further described below in the Detailed Description section. This Summary is not intended to identify key features or essential features of this disclosure&#39;s subject matter, nor is this Summary intended as an aid in determining the scope of the disclosed subject matter. 
     Aspects of the present disclosure meet the above-identified needs by providing apparatus, systems, and methods which facilitate a significant reduction of wasted logistical mass, as well as a reduction in the volume of trash storage. A recycler device is provided which converts what was previously waste into a filament. Other materials such as in-situ resources, useful objects, and the like may also be converted into filament. In some aspects, the filament produced may be used by an additive manufacturing device to manufacture tools, new replacement parts, and a variety of other functional parts without the need for a resupply operation. Conversion of trash to filament may also reduce volume devoted to trash storage and enable converted materials to be stored in a wider variety of locations. Such apparatus, systems, and methods may be utilized aboard spacecraft, space habitats, during long duration explorations, at remote outposts, aboard naval vessels, and other locations and environments apparent to those having skill in the relevant art(s) after reading the description herein. 
     Aspects of the present disclosure facilitate maximizing available resources by turning trash into useful feedstock, such as a filament. The feedstock may be used to fabricate functional parts using an additive manufacturing device. The recycler devices of the present disclosure are designed for simple and safe operation, while minimizing required personnel interaction. The recycler device will accept trash materials with various compositions and create feedstock that is compatible with additive manufacturing machines on Earth and at off-Earth locations. 
     In an aspect, a recycler device is provided comprising a material control system, a material size reducer, an extrusion mechanism, and a spooling assembly. Trash, in-situ materials, or other items for recycling are placed in the material control system. The material control system and the material size reducer sequentially reduce the size of the materials placed into the recycler device and force the materials through each portion of the recycler device. The extruder converts the material into a filament. The filament is then may be spooled by the spooling assembly. The filament produced may be used by an additive manufacturing device to produce new parts. The filament may also be stored for future use or disposal. The spooling assembly may spool the filament onto a spool adapted for use by an additive manufacturing device to produce parts. 
     In an aspect, a recycler device is provided which is configured to satisfy all NASA requirements and regulations for flight and operation aboard the International Space Station. In another aspect, a recycler device is provided which is configured to comply with NASA&#39;s Planetary Protection Policy. 
     In various aspects of the present disclosure, a recycler device is provided which may operate in an office, in a home, in an industrial setting, in a research laboratory, and aboard naval vessels (e.g., ships, submarines), particularly in enclosed locations. The recycler device may be utilized at remote locations, isolated locations, or facilitate waste reduction and management in industrial settings. The present recycler devices may be utilized to recycle parts previously manufactured by additive manufacturing processes or other processes. 
     Apparatus, systems and methods of the present disclosure facilitate reducing the burden of trash aboard the ISS. In the case of the ISS resupply missions, if a resupply spacecraft is capable of returning to Earth and being recovered (e.g., the Dragon capsule), it is loaded with science experiments, old station hardware, equipment, and trash. The spacecraft is then launched, returning to Earth for recovery. If the spacecraft is not capable of being recovered, the spacecraft is typically loaded with trash and launched, where it burns up on reentry. In both cases, reducing the volume and mass of trash would reduce operational pressures for the ISS. Where the spacecraft is capable of returning to Earth, more volume and mass would be available for returning useful payloads to Earth (e.g., scientific experiments). Where the spacecraft disintegrates on reentry, reducing the amount or volume of waste may reduce the need to dispose of trash and increase the amount of trash that can be disposed of per spacecraft. The recycler device of the present disclosure enables conversion of trash into usable filament for additive manufacturing devices. Surplus filament or unusable filament may be stored for later disposable. Such filament also occupies a smaller volume than trash stored using conventional “store and return” methods. 
     Creation of filament from surplus materials, trash, or in-situ materials facilitates utilization of additive manufacturing devices on location (e.g., aboard a spacecraft, aboard the ISS, aboard a submarine). Parts, tools, upgrades, and the like may be created on-demand, rather than waiting for a resupply mission, thus saving time, mass, material, overhead, and transportation while increasing safety and redundancy. In an emergency, the exact solution part may be created. 
     Filament may be created from polymers, metals, and other materials that are capable of being broken down and reconstituted. Filament may be made from or constitute any type of thermoplastic, plastic, metal, composites, resins, virgin materials or any other material or combination of materials apparent to those skilled in the relevant art(s) after reading the description herein. 
     In an aspect, a recycler device is provided which is gravity independent, allowing for nominal operation regardless of the gravity, vibration, or force environment in which the recycler device is placed. 
     In various aspects, the recycler device of the present disclosure may be utilized to mitigate waste management problems (e.g., compact storage, lack of recycling opportunities) in other environments such as long duration explorations, remote outposts, naval vessels, and the like. 
     Plastic packaging is a significant component of common waste produced on spacecraft, space stations, remote outposts, naval vessels and the like. In fact, studies have shown that for a one-year mission away from earth, 15% of the estimated 588 kilograms of food mass necessary would be packaging. Such packaging is often plastic. Such material can be repurposed by a recycler device in accordance with the present disclosure into additive manufacturing feedstock in order to create items that are useful for the mission, reducing the need to launch those items. Because launch costs can be $10,000/kilogram or more, significant savings can be realized. 
     Further features and advantages of the present disclosure, as well as the structure and operation of various aspects of the present disclosure, are described in detail below with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and advantages of the present disclosure will become more apparent from the Detailed Description set forth below when taken in conjunction with the drawings in which like reference numbers indicate identical or functionally similar elements. 
         FIG. 1  is a block diagram of a recycler device, according to an aspect of the present disclosure. 
         FIG. 2  is a schematic of a recycler device, according to an aspect of the present disclosure. 
         FIG. 3  is a block diagram of an exemplary additive manufacturing device, according to an aspect of the present disclosure. 
         FIG. 4  is a flowchart depicting an exemplary process for recycling materials using a recycler device, according to an aspect of the present disclosure. 
         FIG. 5  is an image of filament which has been produced by a recycler device, according to an aspect of the present disclosure. 
         FIG. 6  is an image of a part created by an additive manufacturing device wherein filament produced by a recycler device was utilized, according to an aspect of the present disclosure. 
         FIG. 7  is a front perspective view of a recycler device, according to an aspect of the present disclosure. 
         FIG. 8  is a rear exploded view of a recycler device, according to an aspect of the present disclosure. 
         FIG. 9  is a perspective view of internal systems of a recycler device, according to an aspect of the present disclosure. 
         FIG. 10  is a perspective view of a material processing system of a recycler device, according to an aspect of the present disclosure. 
         FIG. 11  is a perspective view of a material processing system of a recycler device, the loading area being opened to receive materials for processing, according to an aspect of the present disclosure. 
         FIG. 12  is a side, cutaway view of a material processing system showing internal structure and components including the material size reducer, according to an aspect of the present disclosure. 
         FIG. 13  is a perspective view of a material processing system receiving a part to be processed, according to an aspect of the present disclosure. 
         FIG. 14  is an exploded view of a material processing system, according to an aspect of the present disclosure. 
         FIG. 15  is a front view of a grinding component of a material processing system, according to an aspect of the present disclosure. 
         FIG. 16  is a side cutaway view along cut line A of the grinding component of  FIG. 15 . 
         FIGS. 17A and 17B  are images of various material control system configurations which may be implemented within the material processing system and/or other portions of a recycler device, according to various aspects of the present disclosure. 
         FIG. 18  is a perspective view of an extrusion mechanism of a recycler device, according to an aspect of the present disclosure. 
         FIG. 19  is a side cutaway view of the extrusion mechanism of  FIG. 18 . 
         FIG. 20  is a schematic side view of an extrusion mechanism of a recycler device, according to an aspect of the present disclosure. 
         FIG. 21  is an image of various configurations of an auger end portion, according to various aspects of the present disclosure. 
         FIG. 22  is an image of various drive methods for an extruder, according to various aspects of the present disclosure. 
         FIG. 23  is an image of various configurations of an auger portion of an extruder, according to various aspects of the present disclosure. 
         FIG. 24  is an image of various configurations of an extruder, namely the number and arrangement of augers within the extruder, according to various aspects of the present disclosure. 
         FIG. 25  is a side view of a spooling assembly for a recycler device having an outer cover removed, according to an aspect of the present disclosure. 
         FIG. 26  is a perspective view of internal components of a spooling assembly for a recycler device, according to an aspect of the present disclosure. 
         FIG. 27  is an exploded perspective view of a spooling assembly for a recycler device, according to an aspect of the present disclosure. 
         FIG. 28  is a schematic side view of a spooling assembly of a recycler device, according to an aspect of the present disclosure. 
         FIG. 29  is a detail image of a portion of a spooling assembly, according to an aspect of the present disclosure. 
         FIG. 30  is a detail image of a portion of a spooling assembly, according to an aspect of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is directed to apparatus, systems and methods which facilitate a significant reduction of wasted logistical mass, as well as a reduction in the volume of trash storage. In an aspect, a recycler device is provided which converts materials such as old parts, trash, or other waste into a usable form, such as a filament. In some aspects, the filament produced may be used by an additive manufacturing device to manufacture tools, new replacement parts, and a variety of other functional objects. Conversion of trash to filament may also reduce volume devoted to trash storage and enable converted materials to be stored in a wider variety of locations. 
     Apparatus, systems, and methods in accordance with the present disclosure may be utilized aboard spacecraft, space habitats, during long duration explorations, at remote outposts, aboard naval vessels, and other locations and environments apparent to those having skill in the relevant art(s) after reading the description herein. 
     Recycler devices in accordance with the present disclosure may repurpose parts which were improperly additively manufactured into the feedstock utilized, thereby facilitating subsequent attempts to create the desired part without wasting feedstock. Used parts, obsolete parts, single use items, trash and the like may be repurposed into feedstock and subsequently used to print a part that is more immediately useful. In emergency situations or situations with limited supplies, objects may be “cannibalized” into additive manufacturing device feedstock by recycler devices in accordance with the present disclosure and repurposed into needed items by an additive manufacturing device on site, thereby potentially alleviating problems in resource scarce situations or in situations where the right tool is not immediately available because objects without a use can be converted to useful objects. 
     Referring now to  FIG. 1 , a block diagram of a recycler device  100 , according to an aspect of the present disclosure, is shown. 
     Recycler device  100  is configured to accept materials such as trash, broken or obsolete parts, in-situ materials, and the like and convert the materials to a feedstock such as a filament  200  (see  FIG. 2 ). Recycler device  100  may be configured to accept objects made from polymers acrylonitrile butadiene styrene (ABS), polyethylene (PE) (including resealable PE bags such as Ziploc bags available from S. C. Johnson &amp; Son, Inc. of Racine, Wis.), high density polyethylene (HDPE), low density polyethylene (LDPE), nylon, polymer foam, other polymers, monomers, composite materials, metals, resins, virgin materials, in-situ materials, combinations of any of the foregoing and any other material apparent to those skilled in the relevant art(s) after reading the description herein which is capable of being broken down and reconstituted. Such materials are converted into feedstock such as filament  200 . Filament  200  may be any type of thermoplastic or any other material apparent to those skilled in the relevant art(s) after reading the description herein. 
     Recycler device  100  comprises a material processing system  126 , an extrusion mechanism  106 , and a spooling assembly  110 . Material processing system  126  receives material to be processed into filament  202  and breaks down the received material into portions which can be received by extrusion mechanism  106 . Material processing system  126  may include a material control system  102 , a material size reducer  104 , and a loading area  124 . Recycler device  100  may further comprise heating elements  108 , control system  118 , and environmental control  120 . Some or all of the portions of recycler device  100  may be contained within housing  122 . 
     Recycler device may be integral with an additive manufacturing device, such as the additive manufacturing device described with reference to  FIG. 3 . Filament  200  may be fed into the extruder of the additive manufacturing device from recycler device  100 , stored within the combination recycler and additive manufacturing device or stored/used elsewhere. 
     Material control system  102  drives material towards desired locations in recycler device  100 , facilitating processing of material placed in device  100  and moving material through recycler device  100  with or without assistance from external forces such as gravity. As shown in more detail in the various configurations depicted in  FIGS. 17A  &amp; B, material control system  102  may comprise direct or indirect airflow systems (e.g., fans, air compressors) pressure fed systems, or physical contacting devices in order to drive material through recycler device  100 . In another aspect, material control system  102  is a centrifuge which spins recycler device  100 , thereby using centrifugal forces to force material into other properly positioned portions of recycler device  100 . In another aspect, the material is a magnetic or paramagnetic material and material control system comprises electromagnets which drive material through recycler device  100 . 
     In various aspects, material control system  102  includes a loading area  124  which receives material for recycling from users or other devices. Loading area  124  may be a manually operable sliding tray. In other aspects, loading area  124  may include an open volume such as a box or cone where material may be placed for introduction into other portions of device  100  and recycling. Material control system  102  may be an active, electronically controlled (via, for example, control system  118 ) system, ensuring a constant rate of material is delivered to extrusion mechanism  106 . Such system may be gravity-independent. Such operation ensures that breakages do not occur in filament  200 . Spooling filament  200  as it is created also reduces the threat of newly created filament breaking 
     Size reducer  104  reduces the size of materials inserted into recycler device  100  from their original size to a shape and size suitable for use in extrusion mechanism  106 . Size reducer  104  may shred, grind, cut, and/or pulverize material into portions small enough for utilization by extrusion mechanism  106 . In an aspect, extruder requires materials no larger than three millimeters in diameter. In such an aspect, size reducer  104  is configured to break material apart into portions no larger than three millimeters in diameter. 
     In some aspects, material size reducer  104  and/or other portions of material processing system  126  includes heating elements configured to heat material within size reducer  104  in order to make the material more malleable, melt some or all of the material, or otherwise facilitate reduction of the size of pieces of the material. Cooling elements may also be included in order to provide additional control over material temperature. 
     Recycler device  100  may also include one or more material sorting elements. Material sorting elements are configured to sort material inserted into recycler device  100  into various types (e.g., food waste, metal, aluminum, ferrous metal, non-ferrous metal, plastic and the like). Sorted material may then be processed by other portions of recycler device  100  in order to create filament  200  having a uniform material make up. Recycler device  100  may also include one or more storage containers for each type of material. Sorted material in the storage containers may be selectively sent into other portions of recycler device  100  in order to be turned into filament  200  containing such material (as a pure filament or mixed with other types of materials). Such containers may include material control sub systems configured to operate like material control system  104  and force material from the container. In other aspects, sorting is done by recycler device  100  users who only place the desired material types in device  100 . 
     Material processing system  126  may include various filters, dehumidifying elements, drying elements, sieves, grates, and the like in order to render processed material suitable for conversion to filament  200  by other portions of recycler device  100 . Material control system  102  actively pushes the material through at least a portion of the device. 
     Extrusion mechanism  106  receives material from size reducer  104 , further manipulates the size and shape of the material, heats the material via one or more attached heating elements  108  and pushes the pliable or molten material through a die in order to create filament  200  or other feedstock. Material may be moved through extrusion mechanism  106  via an auger, a piston, another mechanism apparent to those skilled in the relevant art(s) or a combination thereof. Extrusion mechanism  106  may include one or more flowmeters, heating elements, cooling elements, filters, screens, grates, breaker plates, expansion volumes, gear pumps and the like. Such components may be selected and positioned to reduce impurities in the material, homogenize the mixture of the material, eliminate air bubbles, control flow rate, maintain pressure within the material, and/or reduce temperature variations. Such components may be selected and positioned to facilitate other design constraints apparent to those skilled in the relevant art(s) after reading the description herein. 
     Spooling assembly  110  is configured to receive filament  200  as it exits extrusion mechanism  106  at die  1002  and spool filament  200  onto a spool suitable for utilization by additive manufacturing device  300 , such as a removable filament cartridge. Spooling assembly  110  may comprise a spooling mechanism  112 , such as a rotating wheel configured to receive and spool filament  200 . One or more portions of spooling assembly may be controlled by spooling control  114 . Spooling control  114  may be controlled by an attending technician or controlled by control system  118 . In an aspect, filament  200  is spooled within a removable cartridge  116  configured to connect to an additive manufacturing device and provide filament for its utilization. In one such aspect, within cartridge enclosure, filament  200  is fed through the center of the spool and exits cartridge  116  from a side panel of cartridge  116 . 
     In various aspects, recycler device  100  is configured to spool filament  200  directly into a removable cartridge  116 . In an aspect cartridge  116  is configured to be removed from recycler device  100  and interface with an additive manufacturing device. 
     Environmental control  120  is configured to monitor and regulate the environment of recycler device  100 . In an aspect, environmental control  120  is comprises at least one fan, a temperature regulation device (e.g., a heater, an air conditioning unit), and a filter. Environmental control  120  regulates one or more of: temperature, humidity, and air quality within recycler device  100 , thereby preventing outgas sing and contamination of the environment in which additive manufacturing device  100  is located during operation. Environmental control unit  120  may be configured to filter the device  100  environment for a preset amount of time after operation or until contaminants are reduced below a specified level and then signal that device  100  is safe to access. 
     Recycler device  100  may comprise housing  122  which contains each element of recycler device  100 , enabling control of the environment of recycler device  100  by environmental control  120 . Housing  122  may be airtight, preventing contaminants from escaping into the surrounding environment from recycler device  100  and vice versa. 
     Control system  118  may be software, hardware, or a combination of software and hardware. Control system  306  is configured to facilitate and control operation of recycler device  120 , converting materials inserted into recycler device  100  into feedstock or another form, such as filament  200 , facilitating safe operation of device  100 , and/or monitoring and tracking production of device  100 . 
     Recycler device  100  is configured to control the movement of the material throughout each portion of recycler device  100  as the material is converted to filament  200 . Material is guided into extrusion mechanism  106  in a controlled manner in order to avoid air pockets or other gaps. 
     In an aspect, recycler device  100  is configured to meet all power, volume, mass, and safety requirements for operation aboard the ISS. In another aspect, recycler device  100  is configured to operate aboard a naval vessel, including a vessel underway. 
     Recycler device  100  may be adapted for use in a variety of environments, including in an office, in a home, in an industrial setting, in a research laboratory, and aboard naval vessels (e.g., ships, submarines), particularly in enclosed locations. Other locales where recycler device  100  may be utilized include remote locations, isolated locations, and in space. 
     Referring now to  FIG. 2 , a schematic of recycler device  100 , according to an aspect of the present disclosure, is shown. 
     Recycler device  100  may comprise one or more hoppers  202 . Hopper  202  holds material as it proceeds from one portion of recycler device  100  to another. In an aspect in accordance with  FIG. 2 , hopper  202  is positioned between material control system  102  and size reducer  104 . Hopper  202  is a funnel which guides material into size reducer  104 . Recycler device  100  may include multiple hoppers  202  and a hopper selector which allows material from a selected hopper  202  to enter size reducer  104 . Each hopper  202  may be designated for a different material type. 
     In an aspect in accordance with  FIG. 5A , hopper  202  is positioned between size reducer  104  and extrusion mechanism  106 . Hopper  202  comprises a funnel and a tube. Hopper  202  guides material from size reducer  104  to extruder. In other aspects, hopper  202  is positioned before material control system  102 . 
     Hopper  202  may comprise an access point (e.g., a door) where materials to be converted into filament  200  are inserted into recycler device  100 . In another aspect, materials are inserted into recycler device via an access point on housing  122 . 
     Referring now to  FIG. 3 , a block diagram of an exemplary additive manufacturing device  300 , according to an aspect of the present disclosure, is shown. 
     In an aspect, additive manufacturing device  300  is configured to produce parts  600  ( FIG. 6 ) using filament  200  produced by recycler device  100 . Additive manufacturing device  300  may be configured to utilize polymer filament  200 , metal filament  200 , filament  200  made from a mixture of materials, and the like. 
     Additive manufacturing device  300  comprises a filament extruder  302  positionable in two axes (e.g., x and y axes). Additive manufacturing device  300  may be a fused deposition-type device or any other additive manufacturing device apparent to those skilled in the relevant art after reading the description herein, including but not limited to a stereolithographic device, an electron beam freeform fabrication device, and a selective laser sintering device. 
     Additive manufacturing device  300  may be located on Earth, on another celestial body, in space, or aboard a space habitat or on a spacecraft. 
     Additive manufacturing device  300  further comprises a build platform  304  positionable in a third axis (e.g., the z-axis). Build platform  304  is configured to support parts as they are being constructed. In another aspect, build platform  304  is omitted. Build platform  304  is a support which holds another part, thereby enabling additive manufacturing device  300  to add additional portions (i.e., layers) to the part being held. Actuators (not shown) are attached to filament extruder  302  and build platform  304 . In an aspect, additive manufacturing device  300  comprises one actuator for each axis. 
     Filament extruder  302  is adapted to create a desired part on build platform  304  via deposition of a polymer or other material. Deposition may be done in an additive manner, such as a layer-wise or raster pattern. The positions of filament extruder  302  and build platform  304  during construction may be controlled by a build control module  306 , electrically connected to each actuator. Build control module  306  may be software, hardware, or a combination of software and hardware. Build control module  306  is configured to cause the desired part (e.g., a support structure) to be produced by additive manufacturing device  300 . 
     Filament extruder  302  is connected to a feedstock source  308 . Feedstock source  308  houses and supplies material necessary to produce on or more parts via additive manufacturing device  300 . In an aspect, feedstock source  308  is a spool of polymer filament threaded into filament extruder  302 . Extruder  302  is configured to heat the polymer filament to its melting point and deposit the melted polymer in order to form the desired part. In an aspect, feedstock source  308  is cartridge  116  loaded with filament created from recycler device. In an aspect, cartridge  116  is removed from recycler device and mounted on additive manufacturing device  300 . In another aspect, filament  200  is fed from cartridge  116  into extruder, forming a single assembly from recycler device  100  and additive manufacturing device  300 . 
     Environmental control  310  is configured to regulate the environment of additive manufacturing device  300 . In an aspect, environmental control  310  is comprises at least one fan, a temperature regulation device (e.g., a heater, an air conditioning unit), and a filter. Environmental control  310  regulates one or more of: temperature, humidity, and air quality within additive manufacturing device  300 , thereby preventing outgassing and contamination of the environment in which additive manufacturing device  300  is located during operation. Additive manufacturing device  300  may be configured according to the disclosures of U.S. patent application Ser. No. 14/331,729, entitled “Manufacturing in Microgravity and Varying External Force Environments”, filed on Jul. 15, 2014 by the Applicant and incorporated herein in its entirety. 
     Referring now to  FIG. 4 , a flowchart depicting an exemplary process  400  for recycling materials using recycler device  100 , according to an aspect of the present disclosure, is shown. 
     Process  400 , at least a portion of which may be executed in a microgravity environment such as Earth orbit, another extraterrestrial environment, remote environment or the like, facilitates recycling of material for use in additive manufacturing device  200  or space-efficient storage for later disposal. Process  400  begins at step  402  with control immediately passing to step  404 . 
     At step  404 , material such as packing materials, discarded plastic fasteners, obsolete parts, other trash, in-situ materials, and the like are received at recycler device  100 . In an aspect material is received at material control system  102 . In other aspects, material is received at hopper  202  or another portion of recycler device  202 . In some aspects, the material received is of a single type (e.g., a polymer, metal, in-situ material). In another aspect, multiple types of materials are received. 
     At step  406 , material is guided into size reducer  104  via material control system  102 . Material is then shredded, ground, cut, and/or pulverized into portions small enough for utilization by extrusion mechanism  106 . Material is guided into size reduced via material control system  102  actions. 
     At step  408 , extrusion mechanism  106  receives material from size reducer  104  and converts the material to filament  200 . 
     At step  410 , filament  200  is received by spooling assembly  110 . Spooling assembly  110  spools or otherwise arranges filament  200  for later use, storage, or disposal. 
     Process  400  then terminates at step  412 . 
     Briefly referring now to  FIG. 5 , filament  200  which has been produced by recycler device  200 , according to an aspect of the present disclosure, is shown. 
     Briefly referring now to  FIG. 6 , an image of part  600  created by additive manufacturing device  200  wherein filament  200  produced by recycler device  100  was utilized, according to an aspect of the present disclosure, is shown. 
     Referring now to  FIGS. 7-9 , various views of recycler device  100  and portions thereof, according to various aspects of the present disclosure, are shown. 
     Recycler device  100  may be configured for rack mounting. Removable cartridge  116  interfacing with and/or containing portions of spooling assembly  110  may be accessed from the front of recycler device  100 . A door  702  may cover the front of recycler device  100 , preventing inadvertent actuation of device controls and providing additional protection for the surrounding environment and individuals and equipment therein if device  100  malfunctions. A control and notifications panel  704  may be located on the front of device  100 , viewable through a window in door  702 . Loading area  124  of material processing system  126  may be accessed via a handle  706  or other actuator. 
     Housing  122  may include various removable panels such as electronics access panel  802  and a side panel  804  which facilitate user access, maintenance, repair and upgrading of device  100 . Such panels may include latches or other locking mechanisms or quick release mechanisms in order to facilitate ease of access. Similarly, other components of device  100  may be mounted on panels or within housings positioned to all removal of such components from device  100  via latches, retainers or the like accessible from the exterior of housing  122 . Material processing system  126  and extrusion mechanism  106  may each be mounted on plates which may be detached from housing  122  from the exterior of device  100  and removed. A filter  810  may be contained in a removable filter cover which may be unscrewed by hand and removed from device  100 . Cartridge may be removed via actuation of a latch and sliding cartridge out from device  100 . 
     Filament  200  may be guided from extrusion mechanism  116  to spooling assembly  110  via tubing  902 , channels, or the like. Tubing material may be selected for its anti-bonding properties and heat dissipating properties in order to ensure that newly formed, hot filament  200 , such as a thermoplastic filament does not bind to tubing  902  as it travels to spooling assembly and cools. Tubing  902  is positioned in order to avoid sharp bends or angles which increase the likelihood that filament  200  will bind, pinch or otherwise damage filament  200  or cause its diameter to deviate from a specified optimal size (e.g., 1.75 mm diameter). 
     Referring now to  FIGS. 10-14 , various views of material processing system  126  and portions thereof, according to various aspects of the present disclosure, are shown. 
     Material processing system  126  includes material control system  102  and material size reducer  104 , namely a grinder  1010 , housed within a material processing system housing  1002 . Material control system  102  may include a series of fans  1204  (labelled as fans  1204   a  &amp;  b  in  FIG. 12 ) and a control plate  1108  positioned within loading area  124 , namely within a sliding loading chamber  1004 . Material control system fans  1204  are positioned within fan housing  1110  and are oriented such that fan exhaust pushes material, including smaller particles and fumes, through housing  1002  and toward material size reducer  104 . Control plate  1108  is positioned in front of fans  1204  and, via pusher arm  1206 , moves from a position adjacent fan housing  1110  to an extended position adjacent material size reducer  104 , thereby forcing material placed inside material processing system  126  into material size reducer  104  for processing. Control plate  1108  includes one or more meshes  1402 , grates or other air-permeable materials positioned in front of fans  1204  which permit fan exhaust to pass through control plate  1108  and move material through material processing system  126 . Pusher arm  1206  may be a telescoping or rigid member controlled by control electronics  118 , pushed by a user manipulating an attached handle, or the like. Pusher arm  1206  may be actuated by an electric motor, hydraulics, cables, or the like. As shown in  FIGS. 17A  &amp; B, other mechanisms may be used to feed material through material processing system including fans placed at various points (as in  126   a  and  126   b ), wave or fluid action (as in  126   d ), magnetic control (as in  126   e ), centrifugal forces (as in  126   f ), and the like. 
     Loading chamber  1004  may be positioned at a front end of rectangular housing  1002  and slide in an out of housing  1002 . A handle  706  may be located on a front side of loading chamber  1004 , enabling users to open loading chamber  1004 . Handle  706  may include a trigger  1014  or other actuator which may unlock loading chamber  1004 . Loading chamber  1004  includes two actuated access doors  1102  (labelled as access doors  1102   a  &amp;  b  in  FIG. 11 ) on the top side of loading chamber  1004 . When loading chamber  1004  is pulled out of housing  1002 , access doors  1102  open, thereby allowing material such as a part  1302  to be placed in device  100  for repurposing. Access doors  1102  may be manually, mechanically (e.g., spring loaded) or electrically controlled. In some aspects, loading chamber volume  1106  may be 6 cm×12 cm×6 cm. Loading chamber  1004  includes material processing system doors  1104  which form a rear wall of loading chamber  1004 . Material processing system doors  1104  open toward material size reducer  104  and close prior to the opening of access doors  1102 , preventing backflow of material once it has been moved toward material size reducer  104 . 
     Housing  1002  may include a dehumidifier element  1012  positioned before material size reducer  104  in order to reduce water present in the material before processing. Hydrolysis negatively affects the quality of filament  200  produced by device  100 . Dehumidifier element  1012  reduces water content, thereby reducing hydrolysis. 
     Grinder  1010  includes one or more sets of rotating blades  1202  (labeled as rotating blades  1202   a  &amp;  b  in  FIG. 12 ) selected to reduce the size of material put in device  100  to a size useable by extrusion mechanism  106 . Grinder  1010  is controlled by a motor and granulates material into small pieces (e.g., 3 mm pieces). The rear face of grinder  1010  may include a sieve having openings sized to allow through only pieces small enough for extrusion mechanism  106 . 
     Once the material is processed by material size reducer  104  (e.g., grinder  1010 ), the material is channeled to extrusion mechanism by a funnel  1006 . In some aspects, funnel is part of a dryer system  1208  positioned after material size reducer  104  to further reduce water content and avoid hydrolysis. Dryer system may include a chamber having funnel as an opening to extrusion mechanism  106  and a drying fan  1008 . 
     Material processing system  126  may include one or more sensors to monitor conditions within material processing system  126  and progress of material being processed by material processing system  126 . The operation of all or portions of material processing system  126  including access doors  1102 , material processing system doors  1104 , material control system  102 , material size reducer  104 , dehumidifier element  1012 , and drying fan  1008  may be controlled by controlling electronics  118 . Operation of such systems may be controlled according to programmed timing and steps, based on sensor readings, or a combination thereof. 
     Referring now to  FIGS. 15 and 16 , a front view and a cutaway view of an exemplary material size reducer  104 , namely grinder  1010 , according to various aspects of the present disclosure, are shown. Material size reducer  104  may multiple rotating blades  1202 . Each set of blades  1202  may be mounted on a ball bearing and controlled by a motor. Material is inserted into a first portion of material size reducer  104 , blades  1202  cut and crush the material into the desired size and shape. Blade sets  1202  may be arranged in order of fineness in order to facilitate efficient cutting of material. As will be apparent to those skilled in the relevant art(s) after reading the description herein, other mechanisms for reducing material size may be employed apart from or in addition to blades. 
     Referring now to  FIGS. 18-24 , various views of extrusion mechanism  106  and portions thereof, according to various aspects of the present disclosure, are shown. 
     Extrusion mechanism  106  moves processed material through a series of heaters which melts the material, passes the material through a series of breaker plates and other components to uniform the flow, and then finally through a die that controls the filament diameter. Extrusion mechanism  106  ensures that a constant feed rate is established while maintaining steady heating and thermal management. 
     Extrusion mechanism  106  may include a material opening  1804  configured to receive processed material from material processing system  126  and introduce the material to auger  1902 . Auger  1902  is driven by an auger motor  1820  and forces material down barrel  1810 . In some aspects, auger  1902  is connected to auger motor  1820  via a gear box.  FIG. 22  depicts various configurations for driving auger  1902 , including a direct drive system  2202 , a gear box system  2204 , a belt drive system  2206 , a piston drive system  2208  and a combination piston and motor system  2210 . Auger  1902  is housed with a barrel  1810 . Barrel  1810  is supported by support arms  1808  and heated by heaters such as band heaters  1806  (labelled as band heaters  1806   a - d  in  FIG. 18 ). Extrusion mechanism  106  may be mounted within device  100  via one or more brackets  1822 . Depending on the material being processed, auger  1902  rotation speed may be varied and the temperature of barrel  1810  may be altered by the heaters. For example, barrel  1810  may be heated to 240° C. in order to melt plastic material in extrusion mechanism  106 . 
     A gear pump  1812  is connected to the end of barrel  1810  and receives molten material. Gear pump  1812  is driven by a gear pump motor  1818  and alleviates variations in pressure and creates a constant flow of amorphous material, thereby facilitating creation of an unbroken line of filament  200 . Mesh screens and a breaker plate  1906  may be positioned after gear pump in order to eliminate contaminants and facilitate consistent filament  200  extrusion. Material then passes into a pipe reducer  1814  and into a die  1904  which shapes and extrudes filament  200 . A filament cooler  1816 , such as a bladeless fan, may be positioned adjacent to die  1814  in order to cool newly formed filament  200 . Filament  200  enters tubing  902  and travels to spooling assembly  110 . 
     As shown in  FIGS. 23 and 24 , extrusion mechanism  106  may include augers  1902  with a variety of profiles including a metered auger  1902   c , a constant auger  1902   b  and a metered auger  1902   a  having a relief section  2302 . Auger-based extrusion mechanism  106  may comprise one auger  106   a , two augers  106   b  or a combination system  106   c . Auger end portion  1302  may be configured in a variety of ways, such as those shown in  FIG. 21  in order to facilitate creation of filament  200 . 
     Referring now to  FIGS. 25-30 , various views of spooling assembly  110  and portions thereof, according to various aspects of the present disclosure, are shown. 
     As will be apparent to those skilled in the relevant art(s) after reading the description herein, some or all of spooling assembly  110  may be contained within a removable cartridge  116 . In other aspects, only spool  2510  is removable from device  100 . In yet other aspects, no portion of spooling assembly  110  is removable from device  100 . In such aspects, filament  200  may be fed from device  100  to additive manufacturing device  300 , external spools, or other devices. 
     In an aspect, spooling assembly  110  begins by cooling filament  200  via, for example, one or more fans, as it exits the extrusion mechanism  106  in order to avoid any unintended deformation as filament  200  is being spooled. Feedback from the extruder mechanism  106  regarding internal pressures of the material being extruded may be received by controlling electronics  118  and will determine the rate at which filament  200  is spooled. This aids in maintaining a constant diameter on filament  200  being produced. Filament  200  may be fed into feedstock cartridge  116  through a center hub using the same filament guide tube that feedstock cartridge  116  uses to dispense the feedstock into additive manufacturing device  300 . 
     Spooling assembly  110  may include a spool assembly casing  2504  enclosing a spool  2510  rotating on a slip ring  2508 . In some aspects, casing  2504  is cartridge  116 . Slip ring  2508  may house a feedstock guide tube which exists spool assembly casing  2504  via a spool assembly casing cover  2708 . Spooling assembly  110  includes a filament securing mechanism  2512  configured to secure a leading end of filament  200  to spool  2510  for winding. In some aspects, filament securing mechanism is a linear actuator having a toothed end attachment which latches onto the leading end of filament  200  after filament  200  is detected entering spooling assembly  110  and has traveled a sufficient distance to be secured by filament securing mechanism  2512 . In other aspects, filament securing mechanism  2512  includes a sensor which detects when the leading end of filament  200  is and secures filament  200  based on such readings. In another aspect, filament securing mechanism  2512  is a passive channel, hole, series of holes, or another configuration apparent to those skilled in the relevant art(s) after reading the description herein. In some aspects, filament securing mechanism  2512  is omitted. 
     During filament  200  creation, spool  2510  is rotated by a spool motor  2506  in order to ensure uniform distribution of filament on spool and to avoid binding, pinching or otherwise damaging filament  200 . Spool motor  2506  may have a gear interfacing with a geared perimeter of spool  2510 . In other aspects, spool motor  2506  drives spool  2510  via a belt. 
     A filament level detector  2502  may be included in spooling assembly  110  in order to detect the amount of filament on spool  2510 . Filament level detector may be a flex sensor positioned to contact filament  200  spooled on spool  2510  and deflect, thereby indicating a filament level. In other aspects, the amount of filament  200  on spool  2510  is determined by the length of filament  200  produced by extrusion mechanism  106 , how much material has been placed in material processing system  126 , how much filament has entered spool assembly casing  2504 , or a combination thereof. Multiple indications of filament level may be recorded. 
     Filament  200  may be spooled by spooling assembly  200  by first traveling through a set of filament rollers  2704  near die  1904 . A funnel  2706  may be positioned after filament rollers  2704  which guides filament  200  into tubing  902 . A filament cutter  2702  may be located before filament rollers  2704  and controlled by controlling electronics  118 . Cutter  2702  may cut filament  200  when extrusion mechanism  106  has extruded all material supplied to it, thereby ensuring that filament has a clean end portion. Device  100  may include multiple filament cutters. Tubing  902  may extend to cartridge  116  such as housing  2504 . Cartridge rollers  2518  inside housing  2504  receive filament  200  and filament speed is controlled by filament feeding mechanism  2518 . Filament feeding mechanism  2518  may be a line winder or other motorized component. Filament  200  is detected by a filament detector  2520  positioned inside housing  2504 . Filament detector  2520  may be a phototransistor configured to detect the presence of filament  200  as well as breaks in filament  200 . Filament  200  is guided to spool  2510  via a tubing  2522  and placed on spool  2510  by a filament winder  2524  which oscillates across the width of spool  2510 , thereby evenly distributing filament  200 . A power and data connection  2514  connects spooling assembly  110  to controlling electronics  118  allowing controlling electronics  118  to regulate and monitor spooling assembly  110  activity. For example, spool motor  2506  and filament winder  2524  speed may be determined by the speed of incoming filament detected by, for example a photo sensor  2802  positioned within housing  2504  and/or filament detector  2520 . A latch  2516  may be released by a user in order to remove housing  2504  from device  100  for use or storage elsewhere. In some aspects, filament  200  is dispensed from housing  2504  via opening it initially entered housing  2504 . As shown in  FIGS. 29 and 30 , spooling assembly  110  may include multiple rollers or other guides in order to control filament  200 . 
     Controlling electronics  118  may be connected to a plurality of sensors distributed throughout device  100  in order to control and regulate the operation of device  100  and produce continuous filament  200  having a uniform diameter and other characteristics while remaining within operational tolerances. Sensors include but are not limited to flowmeters, pressure sensors, temperature sensors, contaminant sensors, and the like. Thermal management will be monitored to establish proper heating and cooling, as well as having emergency cutoff circuits in the event of off nominal heating. 
     While various aspects of the present disclosure have been described herein, it should be understood that they have been presented by way of example and not limitation. It will be apparent to persons skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope of the present disclosure. Thus, the present disclosure should not be limited by any of the above described exemplary aspects, but should be defined only in accordance with the following claims and their equivalents. 
     In addition, it should be understood that the figures in the attachments, which highlight the structure, methodology, functionality and advantages of the present disclosure, are presented for example purposes only. The present disclosure is sufficiently flexible and configurable, such that it may be implemented in ways other than that shown in the accompanying figures. As will be appreciated by those skilled in the relevant art(s) after reading the description herein, certain features from different aspects of the systems, apparatus and methods of the present disclosure may be combined to form yet new aspects of the present disclosure. 
     Further, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public generally and especially the scientists, engineers and practitioners in the relevant art(s) who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of this technical disclosure. The Abstract is not intended to be limiting as to the scope of the present disclosure in any way.