Distributed recycling and additive manufacturing (DRAM) holds enormous promise for enabling a circular economy. Most DRAM studies have focused on single thermoplastic waste stream. This study takes three paths forward from the previous literature: 1) expanding DRAM into high-performance polycarbonate/ acrylonitrile butadiene styrene (PC/ABS) blends, 2) extending PC/ABS blend research into both recycled materials and into direct fused granular fabrication (FGF) 3-D printing and 3) demonstrating the potential of using recycled PC/ABS feedstocks for new applications in circular economy contexts. A commercial open source large-format FGF 3-D printer was modified and used to assess the different printability and accuracy of recycled PC and PC/ABS. The mechanical properties (tensile and impact) following the ASTM D638 and D6110–18 standards were quantified. A weather simulation test (ASTM D5071–06) was performed to assess outdoor performance. Finally, two applications in sporting goods and furniture were demonstrated. In general, better printability was achieved with recycled PC/ABS compared to recycled PC, as well as good dimensional accuracy at printing speeds of 30 and 40 mm/s. Minimal qualitative differences and discoloration were visible on the samples after accelerated weather exposure, with results in accordance with the state-of-the-art. The rPC/ABS results from tensile tests show similar values to those of rPC for elastic modulus (2.1 ± 0.1 GPa), tensile strength (41.6 ± 6.3 MPA), and elongation at break (2.8 ± 0.9%), which are also comparable with previous studied virgin 3-D printed filaments. Similarly, impact energy (115.78 ± 24.40 kJ/m2) and resistance values (810.36 ± 165.77 J/m) are comparable in the two tested formulations, reaching similar results compared to FFF 3-D printed filaments, as well as virgin materials for injection molding. Finally, the two demonstration products in the sporting goods and furniture sectors were successfully fabricated with rPC/ABS, achieving complex patterns and good printing speeds for recycled feedstocks. It is concluded rPC/ABS blends represent a potential high-performance feedstock for DRAM, validating its use in direct FGF 3-D printing systems and potential applications for a circular economy.
Sand plastic composites[edit | edit source]
- The Potential of Replacing Concrete with Sand and Recycled Polycarbonate Composites: Compressive Strength Testing
- Potential of distributed recycling from hybrid manufacturing of 3-D printing and injection molding of stamp sand and acrylonitrile styrene acrylate waste composite
- Evaluation of lab performance of stamp sand and acrylonitrile styrene acrylate waste composites without asphalt as road surface materials
- Technical and Economic Viability of Distributed Recycling of Low-density Polyethylene Water Sachets into Waste Composite Pavement Blocks
See also[edit source]
RepRapable Recyclebot and the Wild West of Recycling[edit source]
Recycling Technology[edit source]
- Recyclebot
- RepRapable Recyclebot: Open source 3-D printable extruder for converting plastic to 3-D printing filament
- Open Source 3-D Filament Diameter Sensor for Recycling, Winding and Additive Manufacturing Machines
- Improving recyclebot concepts
- 3-D Printable Polymer Pelletizer Chopper for Fused Granular Fabrication-Based Additive Manufacturing
- Mechanical Properties of Direct Waste Printing of Polylactic Acid with Universal Pellets Extruder: Comparison to Fused Filament Fabrication on Open-Source Desktop Three-Dimensional Printers
- Fused Particle Fabrication 3-D Printing: Recycled Materials' Optimization and Mechanical Properties
- Multi-material distributed recycling via material extrusion: recycled high density polyethylene and poly (ethylene terephthalate) mixture
- Mechanical Properties and Applications of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing
- Wood Furniture Waste-Based Recycled 3-D Printing Filament
- Solar powered distributed customized manufacturing
- Mechanical Properties of Ultraviolet-Assisted Paste Extrusion and Postextrusion Ultraviolet-Curing of Three-Dimensional Printed Biocomposites
- Open Source Waste Plastic Granulator
- Open-Source Grinding Machine for Compression Screw Manufacturing
- Sustainability and Feasibility Assessment of Distributed E-Waste Recycling using Additive Manufacturing in a Bi-Continental Context
- Finding Ideal Parameters for Recycled Material Fused Particle Fabrication-Based 3D Printing Using an Open Source Software Implementation of Particle Swarm Optimization
- Waste Plastic Direct Extrusion Hangprinter
- Hangprinter for Large Scale Additive Manufacturing using Fused Particle Fabrication with Recycled Plastic and Continuous Feeding
Distributed Recycling LCA[edit source]
- Tightening the loop on the circular economy: Coupled distributed recycling and manufacturing with recyclebot and RepRap 3-D printing
- Technical pathways for distributed recycling of polymer composites for distributed manufacturing: Windshield wiper blades
- Plastic recycling in additive manufacturing: A systematic literature review and opportunities for the circular economy
- Energy Payback Time of a Solar Photovoltaic Powered Waste Plastic Recyclebot System
- Life cycle analysis of distributed recycling of post-consumer high density polyethylene for 3-D printing filament
- Evaluation of Potential Fair Trade Standards for an Ethical 3-D Printing Filament
- Life cycle analysis of distributed polymer recycling
- Distributed recycling of post-consumer plastic waste in rural areas
- Ethical Filament Foundation
- Green Fab Lab Applications of Large-Area Waste Polymer-based Additive Manufacturing
- Systems Analysis for PET and Olefin Polymers in a Circular Economy
- Potential of distributed recycling from hybrid manufacturing of 3-D printing and injection molding of stamp sand and acrylonitrile styrene acrylate waste composite
- Towards Distributed Recycling with Additive Manufacturing of PET Flake Feedstocks
Literature Reviews[edit source]
- Waste plastic extruder: literature review
- Life cycle analysis of polymer recycling literature review
- Solar powered recyclebot literature review
- Waste plastic extruder: literature review
- Life cycle analysis of polymer recycling literature review
Externals[edit source]
- Economist article on U. of Washington's HDPE boat, Oprn3dp.me
- https://ultimaker.com/en/resources/52444-ocean-plastic-community-project
- Another possible solution - reusable containers [1]
- Commercial https://dyzedesign.com/pulsar-pellet-extruder/
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- Cruz, F., Lanza, S., Boudaoud, H., Hoppe, S., & Camargo, M. Polymer Recycling and Additive Manufacturing in an Open Source context: Optimization of processes and methods. [2]
- Investigating Material Degradation through the Recycling of PLA in Additively Manufactured Parts
- Mohammed, M.I., Das, A., Gomez-Kervin, E., Wilson, D. and Gibson, I., EcoPrinting: Investigating the use of 100% recycled Acrylonitrile Butadiene Styrene (ABS) for Additive Manufacturing.
- Kariz, M., Sernek, M., Obućina, M. and Kuzman, M.K., 2017. Effect of wood content in FDM filament on properties of 3D printed parts. Materials Today Communications. [3]
- Kaynak, B., Spoerk, M., Shirole, A., Ziegler, W. and Sapkota, J., 2018. Polypropylene/Cellulose Composites for Material Extrusion Additive Manufacturing. Macromolecular Materials and Engineering, p.1800037. [4]
- O. Martikka et al., "Mechanical Properties of 3D-Printed Wood-Plastic Composites", Key Engineering Materials, Vol. 777, pp. 499-507, 2018 [5]
- Yang, T.C., 2018. Effect of Extrusion Temperature on the Physico-Mechanical Properties of Unidirectional Wood Fiber-Reinforced Polylactic Acid Composite (WFRPC) Components Using Fused Deposition Modeling. Polymers, 10(9), p.976. [6]
- Romani, A., Rognoli, V., & Levi, M. (2021). Design, Materials, and Extrusion-Based Additive Manufacturing in Circular Economy Contexts: From Waste to New Products. Sustainability, 13(13), 7269. https://www.mdpi.com/2071-1050/13/13/7269/pdf