Development of sustainable 3D printing filaments using recycled/virgin ABS blends: Processing and characterization

Waste plastic exposed to the environment creates problems and is of significant concern for all life forms. To reuse the waste plastic in a well-organized manner and make it more productive, extrusion-based additive manufacturing, specially fused deposition modeling technique, can be an effective way. Hence, the primary objective of this work is to reuse ABS waste for developing sustainable three-dimensional printing filaments. A mixed feedstock processing approach is used to develop filaments, in which recycled ABS is blended with virgin ABS in weight ratio of 10%-50%. The rheological and thermo-mechanical properties of the extruded filaments were examined. Results indicated that increasing extrusion temperature from 190 degrees C to 195 degrees C produced significant physical changes in ABS blends. There is a breakdown of styrene acrylonitrile and butadiene component in ABS which causes strain hardening and material stiffening. The Young's modulus, yield strength and ultimate tensile strength of 80% RABS/20% VABS filament were found to be 2329, 34.814 and 40.82 MPa, respectively, which is close to VABS filament. The novel filament produced from recycled/virgin ABS blends has the capability to replace commercially available ABS filaments for fabricating high-quality plastic parts through an additive manufacturing routine.

Automated summary

The utilization of waste plastic through extrusion-based additive manufacturing is investigated as a means to address environmental concerns. A mixed feedstock processing approach is used to develop sustainable three-dimensional printing filaments from recycled ABS blended with virgin ABS. The rheological and thermo-mechanical properties of the extruded filaments are examined, revealing the potential for the novel filament to replace commercially available ABS filaments in fabricating high-quality plastic parts.