3D Printing FFF Feedstocks from Recycled Materials

By Nicole Zander, US Army Research Laboratory

Recycled plastics are excellent candidates for distributed additive manufacturing, in which value-added parts are made at or near the source of the material.  In addition to the substantial benefits from recycling, the ability to print parts on-demand with local materials could be game-changing, particularly for those in remote locations such as forward operating bases.  The use of waste plastics can improve the self-reliance of warfighters in such locations by cutting costs and decreasing the demand for the frequent resupplying of parts by the supply chain.  In addition, in the private sector, decreased cost and increased sustainability could drive a market for recycled additive manufacturing feedstocks, providing a high-value output for used plastics.  In this work, experimentation is conducted to turn waste plastics into filament that can be used in fused filament fabrication.  Parts printed from recycled polyethylene terephthalate had the highest tensile strength of all recycled plastics evaluated (35.1 ± 8 MPa), and were comparable to parts printed from commercial polycarbonate-ABS filament.  Blends of recycled plastics and reinforced plastics were also evaluated.  In addition, three point bending tests showed a similar load at failure for a select long-lead military part printed from the recycled filament compared to parts printed from commercial filament.  Thus filament from recycled polyethylene terephthalate has the capability for replacing commercial filament in printing a diverse range of plastic parts. This research demonstrates some of the first work on the feasibility of using recycled plastic in additive manufacturing.