Boxhead logo black text with black border

Establishment of Boxhead Plastics from First Thought to Production

When the tomato sauce bottle slips out of my shopping bag whilst trying to muscle my purchases into the house from the car I think “phew lucky it was not glass” Why is plastic so useful to us humans yet so harmful to our planet? Why do I want it and hate it at the same time? Can I escape from the guilty feeling of looking around my house to see so much plastic? Who takes responsibility of the environmental concequences of plastic and how? While it may be possible to eliminate some forms of plastics, such as the single use plastic bags, plastic’s versatile and durable nature means it will continue to play a role in our lives.  Which means we’re left with the question of what to do with plastic when it becomes waste?  How can we inventively, and usefully repurpose these materials?

In 2015 I purchasing a desktop 3D filament extruder to experiment with converting  PET bottles into 3D print filament. I also purchased a food dehydrator and a paper shredder. In my tiny unit in Redfern, Sydney, I washed and removed labels from the bottles, cut them up and dried the plastic in the food dehydrator then shredded the plastic into tiny pieces using the paper shredder. I fed the regrind material into the desktop filament extruder in attempts to make 3D print filament.

Throughout 2015 and 2016 I ran many tests using the ground up PET plastic bottles and the filament extruder but due to my lack of technical expertise and available lab equipment I yielded no successful results.

3D Filament Extruder for running tests to recycle plastic

Filastruder and Filawinder

Box I made to test plastic recycling

Handmade Box from Car Bumper Bar

In 2017 I started working with polypropylene car bumper bars. I sanded paint off, cut to size, heated the pieces in the oven then pressed it flat under a weight. I then commenced to artistically glue the pieces together to make small boxes. This is where BoxHead was born.

Hand making these boxes was tricky and time consuming so I decided to look into plastic injection moulding.

In the 2018 I enrolled at Lidcome TAFE Polymer Technician Certificate IV course. I also started volunteer work for Mastroplas. I am continuing to study and work in the indutry abd currently I
I cut the polypropolene car bumper bars into small pieces leaving the paint on, I then granulate it down to 5mm and put the regrind into an injection mould machine to make plastic plates ans two types of golf tees.

Plastic Picnic Plates and Golf Tees Made From 100% Car Bumper Bar Material