Steve Rosewell is keen to race his 3D-printed billycart at this Sunday’s Bangalow Billycart Derby. Pictured is a model version of the completed billycart.
Steve Rosewell is keen to race his 3D-printed billycart at this Sunday’s Bangalow Billycart Derby. Pictured is a model version of the completed billycart. Contributed

3D billycart a contender at Bangalow race day

WHILE many fans build billycarts using boxes and wheels, one Byron Shire resident has built one with recycled materials and a 3D printer.

Steve Rosewell of prop manufacturing company Studio Kite has built a robot that pumps out large-scale, low-resolution 3D printed items including his fancy billycart, made from recycled ABS non-toxic plastic waste.

The waste comes from old items such as car dashboards and doors, plastic toy building blocks, whitegoods and electrical appliance casings.

“As a prop maker my dumpster was always overflowing with polystyrenes, resins and other horrid rubbish,” Mr Rosewell said.

“3D printing ... you only add what you need, so there is no waste – and any mistakes can be chipped and used again.”

Mr Rosewell said apart from being environmentally-friendly, 3D printing with recycled materials could be quick and cheap.

“Billycart printing took about 12 hours but it took a lot longer to do all the planning, put the steering in and to paint it,” he said.

“It might cost $800 to build a 5ft sculpture with your typical building materials, for example, but using recycled materials it might only cost a few dollars.”

He said his billycart was designed to resemble the vehicles of 1960s cartoon characters including the Batmobile and George Jetson’s flying car.

Steve Rosewell beside the robot he built which built his billycart.
Steve Rosewell beside the robot he built which built his billycart. Contributed

The 3D-printed car has been entered in Sunday’s Bangalow Billycart Derby.

“I’ll be racing and a work colleague’s son will race in the kids’ event,” Mr Rosewell said.

“It’s a tough billycart and it has good wheels.

“It kind of feels like the wheelie bin material – that plastic, rubbery feel,” he said.

The derby runs from 9am to 3.15pm.



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