Custom Shredder Blade Geometry for E-Waste Recycling – By DesignWithAjay
At Ajay Industries, we design shredder blades not just to cut—but to intelligently shear, fracture, and separate. E-waste presents one of the most challenging feedstocks in industrial recycling: it’s dense, abrasive, and
heterogeneous. From circuit boards and cables to metal casings and plastic housings, each material demands a different cutting strategy.
This guide outlines how DesignWithAjay develops custom blade geometries specifically optimized for e-waste, combining CAD precision, field data, and modular design principles.
Why E-Waste Requires Specialized Blade Geometry
Unlike uniform materials like HDPE or rubber, e-waste contains:
- Hard metals (aluminum, copper, steel)
- Brittle substrates (PCBs, ceramics)
- Flexible polymers (wires, insulation)
- Abrasive composites (glass-filled plastics)
Generic blade profiles often fail to grip, shear, or fracture these materials effectively—leading to jamming, uneven particle size, and excessive wear.
DesignWithAjay’s Blade Geometry Strategy for E-Waste
1. Multi-Edge Hooked Profiles
- Aggressive hooks grip cables and brittle boards
- Serrated edges initiate fracture in layered substrates
- Variable pitch spacing reduces torque spikes
Ajay Tip: We use parametric CAD to adjust hook depth and angle based on material mix ratios.
2. Staggered Tooth Layout
- Alternating blade heights create multi-point contact
- Improves shearing efficiency and reduces vibration
- Enhances throughput by preventing material bridging
Ajay Tip: Our twin-shaft designs use mirrored stagger patterns for synchronized cutting.
3. Relief Grooves and Chip Breakers
- Grooves reduce friction and heat buildup
- Chip breakers fragment brittle materials into manageable sizes
- Improves downstream separation and sorting
Ajay Tip: We simulate stress zones using SolidWorks Simulation to place grooves precisely.
4. Material Selection and Surface Treatment
- D2 tool steel or EN31 hardened to 58–60 HRC
- Optional coatings: TiN, hard chrome, or nitriding
- Edge retention and corrosion resistance are critical for mixed-metal feedstock
Ajay Tip: Blade wear data is logged and used to refine geometry in future iterations.
Real-World Example: E-Waste Blade Stack #EWS-36
| Feature | Specification |
|---|---|
| Blade Count | 36 (hooked + serrated hybrid) |
| Material | D2 tool steel, hardened |
| Shaft Diameter | 40 mm, keyed |
| Pitch Spacing | Variable (18–24 mm) |
| Coating | Nitrided + polished edges |
| Performance | 520 kg/hr throughput, 0 jams in 6 months |
Outcome: Improved particle uniformity, reduced motor load, and extended blade life in mixed e-waste streams
What You Get with Every DesignWithAjay Blade Kit
- Parametric CAD models with editable geometry
- BOM with material specs and hardness ratings
- Exploded views for assembly and maintenance
- Torque and RPM calculators based on feedstock
- Revision history and field performance notes
Final Thoughts
E-waste recycling demands more than brute force—it requires precision-engineered blade geometry tailored to unpredictable materials. At DesignWithAjay, we combine simulation, field data, and modular design to build shredder blades that perform under pressure and evolve with your recycling needs.
Whether you’re designing a new system or upgrading an existing one, our blade kits help you shred smarter, safer, and more sustainably.