Sustainable Polymer Composites Manufacturing through 3D Printing Technologies by Using Recycled Polymer and Filler

Area of Science:

• Materials Science
• Sustainable Engineering
• Additive Manufacturing

Background:

• Growing ecological concerns over synthetic material disposal necessitate sustainable alternatives and circular economy (CE) approaches.
• Recycling routes and sustainable materials are gaining attention as viable solutions to plastic waste.
• Fused Filament Fabrication (FFF) is a widely used 3D printing technique.

Purpose of the Study:

• To produce and characterize bio-filaments from recycled polylactic acid (PLA) and artisanal ceramic waste for FFF 3D printing.
• To evaluate the physical, thermal, and mechanical properties of the novel bio-filaments.
• To demonstrate the feasibility of using these recycled materials in modified, low-cost FFF printers.

Main Methods:

• Bio-filaments were produced using an extrusion process from recycled PLA and ceramic waste.
• Comprehensive characterization of the filaments included physical, thermal, and mechanical property assessments.
• FFF 3D printing was performed using modified commercial printers to create 3D models.

Main Results:

• The produced filaments exhibited distinct morphological, thermal, rheological, and mechanical properties.
• 3D printed objects from 100% recycled PLA showed reduced mechanical performance compared to other formulations.
• All developed filaments were successfully utilized in a modified, low-cost FFF printer.

Conclusions:

• Recycled PLA and ceramic waste can be repurposed into functional bio-filaments for 3D printing.
• Despite some mechanical limitations, these materials offer a low-cost, environmentally beneficial approach to additive manufacturing.
• This study presents a practical example of material reprocessing and recyclability for sustainable 3D printing applications.