Using waste polymers to create filament for 3D printing of recyclable end-products

Recycling and waste management are hot topics in today’s world, contributing to a more sustainable environment. Proper waste management prepares for better recycling of waste products and materials. The more materials are recycled, the less residual waste is produced, the more raw materials are available, and the less is the human impact on the environment and depletion of the earth.

One of the materials applied a lot in various products we use in our daily lives, are polymers. Plastic pollution is a major threat to our natural ecosystems. Therefore, recycling plastics and polymers is an interesting topic to reduce environmental pollution. This was also the starting point of the AMP-subsidised project Waste2Print, which is around researching and testing the recyclability of polymers and creating filament out of it for 3D printing purposes. This way, the resources and end product could be recyclable too, creating less negative impact and waste.

The Waste2Print consortium consists of Riwald Recycling, 3devo and FIP-AM@UT. Riwald Recycling is a high tech recycling business from Almelo, recycling many hundreds of thousands of tonnes of waste materials every year – ranging from electrical household equipment, to industrial high-quality residual flows, to train sets and aircrafts. 3devo from Utrecht offers high-performance products and services, that transform filament extrusion into a closed-loop circle. They help customers improve their competitive advantage through the customisation of enhanced 3D printing filament. The FIP-AM@UT supports in project management and contributes with their extensive material science expertise.

During the project, the consortium focuses on the innovative process of converting plastic waste into sustainable 3D printing solutions. After recycling thermoplastic polymers and processing them into shredded form, they will be used to create filament for 3D printing. The resulting 3D printed structures effectively repurpose waste materials by transforming them into printing filament, allowing for the creation of new products. These new products will be recyclable as well. This innovative process not only reduces waste but also promotes sustainability by utilising recycled materials in the production cycle.

Industry partners

APPROACH

Waste2Print was divided into six work packages, converting plastic waste into sustainable 3D printing structures. First, suitable polymers for recycling were identified through usecase assessment and material selection. Recycled material can
contain impurities, dirt and dust. It is therefore rinsed, shredded, and pelletized ready for the filament extruder.

Next, extruder parameters and filament production processes were optimized to improve efficiency and quality. The filament was then rigorously tested for quality and printability using 3D printing parameters that ensure effective use of the filament.

Finally, thermo-mechanical testing and validation evaluated the functional properties and suitability of the resulting 3D printed parts. Identical 3D structures are printed using the recycled filament and its fresh counterpart. Comprehensive project management and knowledge dissemination ensured smooth execution and effective sharing of findings with stakeholders.
This methodical approach developed a reliable process, creating high-quality, recyclable 3D printing filament from waste polymers, fostering environmental sustainability and innovative recycling solutions.

OUTCOME

The project successfully addressed the challenge of converting plastic waste into sustainable 3D printing solutions. Various experiments were performed to optimise extrusion heating and cooling zones for filament production. Further experiments identified suitable printer nozzle temperature, material feed, linear traverse speed and cooling requirements for effective 3D printing of the recycled material:
 

• High quality filament based on an optimised set of extrusion parameters
• Successful print job through optimised 3D print parameters
• Up to 80% thermo-mechanical properties compared to fresh material

It is clear therefore that Waste2Print offers a sustainable solution for reusing thermo-plastic polymers in additive manufacturing (3D printing).

This project was made possible through the Regio Deal supported by the Province of Overijssel and the Dutch State.

FOR MORE INFORMATION ABOUT THE WASTE2PRINT, PLEASE FEEL FREE TO REACH OUT TO

Sattar Emamian

Research Engineer

Steijn Jonker

Research Engineer

Ava Ghalayaniesfahani

Research Engineer

Mehrshad Mehrpouya

Assistant Professor