I have to filter out the small stuff and run it through over and over - six cycles resulted in half of the material being small enough for a Filastruder, and the other half still being too large. How's your granulate size consistency?

Not really surprised rock crushers sort the material  anything that makes the grade goes on the offload belt into the truck or on the finish product  conveyor  anything not passing the grate goes on another belt up to the feed hopper to get another cycle through the crusher.
Automating the sort recycle of material would certainly speed things up and save tedious labor.
tin

http://www.amazon.com/Joe-Chipper-CJ601 … od+chipper

It is plenty powerful enough even for 100% infill parts, but the problem I'm facing is that the resulting granulate has a large range - from bigger than a quarter to smaller than a regular ABS pellet. I have to filter out the small stuff and run it through over and over - six cycles resulted in half of the material being small enough for a Filastruder, and the other half still being too large. How's your granulate size consistency?

This is the chipper I use:
http://www.harborfreight.com/14-amp-1-1 … 69293.html
The slot-style opening takes 1.5" max, so I try to make my smallest dimension just under that.  You can buy a drawstring laundry bag at Walmart for $4 to tie to the bottom to catch the plastic.  My first attempt was with a Rubbermaid container but the airflow blew plastic everywhere.

Anyway, I just noticed in my email that through 12/20 you can get 25% off any single item.  If anyone was considering it. It might be a good time.  The coupon has restrictions, but best I could tell it didn't preclude using it with the chipper.