The Use of Fresnel Lens Softening Stations to Improve Recycling Feasibility of Injection-Molding Purges

Injection-molding purges are heterogeneous, bulky residues whose uncertain composition and irregular geometry hinder direct reinsertion, making cold shredding costly and maintenance-intensive. This work develops a low-infrastructure solar-assisted pre-processing route using a PMMA Fresnel lens to induce controlled sub-onset softening and enable clean shear cutting without destructive thermal histories. The sub-onset softening is here defined into a viscoelastically active range (at or above T_g for the amorphous phase) while remaining below the melting onset (T_m, onset) and below the onset of thermal degradation (T_d, onset). The station was engineered via QFD and risk-oriented design tools, while a weighted Pugh matrix selected shear cutting over saw-based alternatives. A screening factorial DOE showed that lens height, angle, and their interaction significantly govern focal-spot diameter and receiver temperature, yielding linear relations for conservative set-point selection. Receiver benchmarking further indicated that copper reaches substantially higher temperatures than graphite under identical exposure conditions, supporting copper as the simplest, rapid-heating receiver. Under DOE-calibrated operation, tear-free shear cutting was achieved across representative purge families (PP–ABS, PC–ABS–PP, PA66, PA66-filler, and POM) without forced convection. From a recycling and waste-management perspective, the approach converts bulky purge scrap into mill-compatible feedstock with reduced mechanical resistance, lowering tool wear and fines generation, accelerating downsizing, and limiting stockpiling that elevates combustible-inventory fire risk. Overall, the proposed DOE-calibrated, operator-friendly framework improves recycling feasibility by enabling safer handling, more stable preprocessing throughput, and reduced reliance on disposal or long-term storage for heterogeneous industrial purges.