Sovereignty Module: Shape the Synthetic
Shape the Synthetic
Complete Plastics, Polymers, and Synthetic Materials Guide
Complete Plastics, Polymers, and Synthetic Materials Guide
Plastics are everywhere in the modern world. After a collapse, salvaging and recycling existing plastics is the first priority. This campaign covers identification, recycling, and basic production of plastics and resins from available feedstocks.
Chapter 1: Plastic Identification
| Code | Name | Properties | Common Items | Recyclable |
|---|---|---|---|---|
| 1 (PET/PETE) | Polyethylene terephthalate | Clear, strong, barrier | Water bottles, food containers | Yes (melt and remold) |
| 2 (HDPE) | High-density polyethylene | Tough, chemical resistant | Milk jugs, pipes, buckets | Yes |
| 3 (PVC) | Polyvinyl chloride | Rigid or flexible, durable | Pipes, wire insulation, flooring | Difficult (releases HCl) |
| 4 (LDPE) | Low-density polyethylene | Flexible, transparent | Bags, squeeze bottles, film | Yes |
| 5 (PP) | Polypropylene | Heat resistant, strong | Containers, rope, auto parts | Yes |
| 6 (PS) | Polystyrene | Rigid or foam, brittle | Cups, insulation, packaging | Difficult |
| 7 (Other) | Various (nylon, ABS, polycarbonate) | Varies | Electronics, mixed products | Varies |
Identification tests: Float test (PE and PP float in water, others sink). Burn test (PE burns like candle wax; PVC self-extinguishes with acrid smell; PS burns with black sooty smoke). Nail test (PE dents, PS cracks).
Chapter 2: Plastic Recycling
| Step | Action | Equipment |
|---|---|---|
| 1 | Sort by type | Visual + identification tests |
| 2 | Clean (remove labels, food, dirt) | Water, scrub brush |
| 3 | Shred into small pieces | Knife, shredder, or hammer |
| 4 | Melt in container | Metal pot, heat source (PE: 250-350F, PP: 320-380F) |
| 5 | Pour into mold or press into shape | Metal, wood, or silicone molds |
| 6 | Cool and remove from mold | Air cool or water quench |
Caution: Do NOT burn PVC (releases toxic hydrogen chloride gas). Melt plastics outdoors or with ventilation. Never overheat (decomposition produces toxic fumes).
Chapter 3: Natural Resins and Plastics
| Material | Source | Properties | Use |
|---|---|---|---|
| Shellac | Lac insect secretion | Hard, glossy, insulating | Coatings, electrical insulation, records |
| Casein plastic (Galalith) | Milk protein + formaldehyde | Hard, polishable | Buttons, knitting needles, decorative items |
| Cellulose acetate | Cotton/wood pulp + acetic acid | Transparent, flexible | Film, eyeglass frames |
| Bakelite (phenolic resin) | Phenol + formaldehyde | Hard, heat-resistant, insulating | Electrical components, handles |
| Rosin (pine resin) | Pine trees | Sticky, waterproof | Adhesives, varnish, solder flux |
| Amber | Fossilized tree resin | Hard, insulating | Jewelry, electrostatic experiments |
| Horn/tortoiseshell | Animal horn, turtle shell | Thermoplastic (heat-moldable) | Combs, buttons, decorative items |
Chapter 4: Casein Plastic Production
The simplest plastic to make from scratch using only milk and an acid.
| Step | Action | Details |
|---|---|---|
| 1 | Heat milk to 120F (not boiling) | Whole milk works best |
| 2 | Add acid (vinegar, 1 tbsp per cup of milk) | Curds form immediately |
| 3 | Strain curds through cloth | Press out all liquid (whey) |
| 4 | Knead curds while warm | Add pigment if desired |
| 5 | Press into mold | Compact firmly |
| 6 | Soak in formaldehyde solution (10%) for 24-48 hours | Cross-links protein (hardens permanently) |
| 7 | Air dry for 1-2 weeks | Becomes hard, polishable plastic |
Without formaldehyde: casein plastic remains somewhat soft and water-sensitive but still useful for buttons, beads, and small items.
Chapter 5: Fiberglass and Composites
| Component | Material | Function |
|---|---|---|
| Reinforcement | Glass fiber cloth, carbon fiber, or natural fiber (hemp, flax) | Provides tensile strength |
| Matrix (resin) | Polyester resin, epoxy, or natural resin (pine pitch + beeswax) | Binds fibers, provides shape |
| Catalyst/hardener | MEKP (for polyester), amine hardener (for epoxy) | Initiates curing |
| Release agent | Wax, PVA film | Prevents sticking to mold |
Layup process: Apply release agent to mold. Lay glass cloth. Brush on catalyzed resin. Roll out air bubbles. Repeat layers for thickness. Cure (room temperature for polyester/epoxy; heat for natural resin). Demold.
Chapter 6: Adhesives
| Adhesive | Ingredients | Strength | Best For |
|---|---|---|---|
| Hide glue | Animal skin/hooves boiled, dried, rehydrated | Good (wood) | Woodworking, bookbinding |
| Casein glue | Milk curds + lime (calcium hydroxide) | Good (water-resistant) | Wood, paper, labels |
| Pine pitch | Heated pine resin + charcoal powder | Moderate | Waterproofing, hafting tools |
| Birch bark tar | Birch bark heated in absence of air | Good | Primitive adhesive (Stone Age tech) |
| Epoxy (if available) | Resin + hardener | Excellent | Metal, glass, structural |
| Flour paste | Flour + water, cooked | Low | Paper, wallpaper, papier-mache |
| Rubber cement | Rubber dissolved in solvent | Moderate (flexible) | Paper, leather, temporary bonds |
Reference Card
- Identify plastics by recycling code (1-7), float test, burn test, and nail test
- PE and PP are easiest to recycle: melt at 250-380F and remold
- NEVER burn PVC: releases toxic hydrogen chloride gas
- Casein plastic (milk + acid + formaldehyde) is the simplest plastic to make from scratch
- Fiberglass: glass cloth + polyester/epoxy resin, layered in a mold and cured
- Hide glue (boiled animal skin) is the strongest traditional wood adhesive
- Pine pitch (heated pine resin + charcoal) waterproofs and bonds since the Stone Age
- Always melt/recycle plastics outdoors or with ventilation to avoid toxic fumes
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