Achieving sustainability by additive manufacturing: a state-of-the-art review and perspectives

Virtual and Physical Prototyping, Journal Year: 2024, Volume and Issue: 19(1)

Published: Dec. 9, 2024

As global awareness of resource scarcity and environmental concerns grows, sustainable manufacturing practices have become imperative. Additive (AM), with its high material efficiency design flexibility, presents a promising pathway toward industrial transformation. This review explores AM's role in sustainability across lifecycle: for AM, after AM. In the AM phase, strategies such as topology optimisation, part consolidation, cellular structures reduce usage enhance durability. During in-situ process monitoring closed-loop control improve reliability, reducing energy consumption failure rates. Meanwhile, adoption materials—metals, polymers, concretes, biomaterials—further strengthens potential to advance sustainability. After applications repair, remanufacturing, recycling extend product lifecycles impact, aligning circular economy principles. Future perspectives include integration artificial intelligence in-process development, along regulatory frameworks critical deployment. Lastly, emerging research trends advancing through are reviewed. Overall, this provides roadmap academia industry, offering insights maximise contribution more responsible future.

Language: Английский

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Creating Sustainable Composites from Pyrolyzed Burlap and Ocean-Recycled Plastics using FDM

ACS Sustainable Chemistry & Engineering, Journal Year: 2024, Volume and Issue: 12(4), P. 1405 - 1419

Published: Jan. 17, 2024

The study focuses on the mechanical performance of a blend ocean-recycled high-density polyethylene (rHDPE) and polypropylene (rPP) explores effect adding burlap biocarbon from post-industrial waste as filler. This aims to upcycle plastic compare conventional injection molding with 3D printing. Taguchi-gray relational analysis was utilized determine preferred printing conditions for both rHDPE–rPP rHDPE–rPP–biocarbon composite. found that were raster angle 0°, speed 900 mm/min, nozzle temperature 215 °C, while composite 1200 255 °C. also compared properties printed injection-molded samples, demonstrating higher tensile flexural moduli percent increase 7 12%, respectively, counterparts. However, no considerable difference in modulus observed between samples Moreover, it addition resulted an enhancement optimized specimen 17 5%, respectively. exhibited decrease impact strength 63 23%,

Language: Английский

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Valorization of Tomato Agricultural Waste for 3D-Printed Polymer Composites Based on Poly(lactic acid)

Polymers, Journal Year: 2024, Volume and Issue: 16(11), P. 1536 - 1536

Published: May 29, 2024

Agricultural waste is a renewable source of lignocellulosic components, which can be processed in variety ways to yield added-value materials for various applications, e.g., polymer composites. However, most biomass incinerated energy. Typically, agricultural left decompose the fields, causing problems such as greenhouse gas release, attracting insects and rodents, impacting soil fertility. This study aims valorise nonedible tomato with no commercial value Additive Manufacturing (AM) create sustainable, cost-effective PLA Fused Filament Fabrication (FFF) filaments 5 10 wt.% stem powder (TSP) were developed, 3D-printed specimens tested. Mechanical testing showed consistent tensile properties 5% TSP addition, while flexural strength decreased, possibly due void formation. Dynamic mechanical analysis (DMA) indicated changes storage modulus damping factor addition. Notably, composites exhibited antioxidant activity, increasing higher content. These findings underscore potential utilization FFF, offering insights into greener management practices addressing challenges performance material compatibility. research highlights viability integrating filament-based AM, contributing sustainable promoting circular economy initiatives.

Language: Английский

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Repetitive recycling effects on mechanical characteristics of poly‐lactic acid and PLA/spent coffee grounds composite used for 3D printing filament

Polymer Engineering and Science, Journal Year: 2024, Volume and Issue: 64(11), P. 5613 - 5626

Published: Aug. 29, 2024

Abstract Due to its biodegradability, biocompatibility, and mechanical properties, poly‐lactic acid (PLA) is a leading biomaterial for numerous applications, especially fused deposition modeling filament fabrication. Nonetheless, the absence of comprehensive recycling strategy may emerge as significant source plastic pollution in future. Indeed, polymer undergoes deterioration during melt recycling, resulting decrease some properties that can compromise recyclability. To improve recycled PLA, utilization organic fillers coming from renewable materials be considered sustainable solution. The objective this work then evaluate effect (reprocessing) on virgin raw material well biocomposites based spent coffee grounds (incorporating 5% spend weight). different types filaments are extruded re‐extruded characterized under tensile, flow index, hardness tests. results show increase number extrusions whether PLA or composite contributes diameter fluctuation. Regarding tensile rise frequency shows weakness strength elongation at break. On other hand, Young's modulus values exhibit fluctuations. Concerning addition filler, no major enhancement observed break, which attributed poor adhesion between matrix filler. process affects an these values, those composite, associated with increased crystallinity caused by SCG incorporation. Highlights Recycling reusability PLA/spent (SCG) filaments. Assessment effects PLA/SCG. Mechanical characterization through testing.

Language: Английский

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Biodegradable cellulose ester blends: studies, compatibilization, biodegradable behavior, and applications. A review

Progress in Polymer Science, Journal Year: 2024, Volume and Issue: unknown, P. 101919 - 101919

Published: Dec. 1, 2024

Language: Английский

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Heat-Responsive PLA/PU/MXene Shape Memory Polymer Blend Nanocomposite: Mechanical, Thermal, and Shape Memory Properties

Polymers, Journal Year: 2025, Volume and Issue: 17(3), P. 338 - 338

Published: Jan. 26, 2025

This study investigates the fabrication and characterization of heat-responsive PLA/PU/MXene shape memory polymer blend nanocomposites with varying PLA content (10, 20, 30, 50%) a fixed MXene 0.5 wt.%. The results indicate significant improvements in mechanical properties, 50% showing 300% increase ultimate tensile strength 90% decrease % elongation compared to pure PU. Additionally, exhibited 400% flexural strength. Microstructural analysis revealed dispersed pores sea–island morphology PU blend. Thermal using DSC showed an crystallinity from 33% (pure PU) 45% for blend, indicating enhanced crystalline domains due semi-crystalline nature MXene’s influence on molecular ordering. TGA demonstrated improvement thermal stability, onset temperature rising 185 °C 212 degradation increasing 370 425 attributed rigid structure stabilizing effect. Shape testing that 30% achieved best fixity recovery optimal performance, whereas higher diminished behavior.

Language: Английский

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Sustainable Procedures for the Recycling of Waste Building Materials: The Creative Recycling of Window Frames

Sustainability, Journal Year: 2025, Volume and Issue: 17(5), P. 1793 - 1793

Published: Feb. 20, 2025

Upcycling is identified as a process of the transformation waste materials to which it possible give value artistic or environmental quality. To date, greatest use upcycling can be found in design, art and fashion sectors. As other sectors, one biggest challenges construction industry future search for new ways reuse discarded materials. In this sense, technique recovery removed but with much lower energy resources than regeneration recycled material. With respect these issues, aim paper present results design experimentation aimed at defining methodologies tools building components from decommissioning renovation processes existing buildings, an approach that integrates both disassembling re-assembling elements, line sustainable development climate neutrality goals European Union aims achieve by 2050. The methodology used made field experiment means creation prototype evaluate study which, if on hand define appropriate procedure upcycling, highlighted how procedures save reduce emission CO2 environment. specific case, gave following results: savings 2038.92 kWh; reduction 641.80 kg compared similar intervention scratch. Therefore, definition replicable scalable operational activity applied architecture allows, those elements still have useful life, can, therefore, architecture, profitable contribution circular economy.

Language: Английский

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Exploring the applicative potential of polyimides containing DOPO-functionalized triazine through straightforward blending technique

Journal of Materials Science, Journal Year: 2025, Volume and Issue: unknown

Published: March 11, 2025

Language: Английский

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Recycling Post-Consumed Polylactic Acid Waste Through Three-Dimensional Printing: Technical vs. Resource Efficiency Benefits

Sustainability, Journal Year: 2025, Volume and Issue: 17(6), P. 2484 - 2484

Published: March 12, 2025

The linear “take–make–dispose” model of plastic consumption has led to significant environmental challenges and unplanned waste legacies, emphasising the need for more sustainable recycling practices. This study explored integration post-consumer recycled polylactic acid (rPLA) into 3D printing filaments as a step towards manufacturing. Using 100% virgin PLA (vPLA) baseline, were produced with rPLA-to-vPLA ratios 0%, 25%, 50%, 75%, evaluated surface roughness, tensile strength, flexural properties, hardness. results revealed that increasing rPLA content negatively affects mechanical properties quality. Surface roughness increased from 7.06 µm pure vPLA 10.50 rPLA, whilst strengths decreased by 48.4% 49%, respectively, compared vPLA. Hardness also declined, showing 7.5% reduction relative Despite these reductions, blends up 50% retained over 90% performance vPLA, demonstrating viable compromise between sustainability. Morphological analysis highlighted poor interlayer adhesion void formation primary causes degradation in higher blends. challenges, this demonstrated rPLA-vPLA can extend life cycle promote manufacturing By addressing polymer research supports materials printing, contributing circular economy goals recycling, resource efficiency, production outcomes.

Language: Английский

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Reinforced Polymer Composite Filaments in Fused Deposition Modeling of 3D Printing Technology: A Review

Advanced Engineering Materials, Journal Year: 2025, Volume and Issue: unknown

Published: March 3, 2025

Fused deposition modeling (FDM) is one of the most commonly used 3D printing techniques. FDM uses thermoplastics to manufacture final product. This review article provides a comprehensive overview use composite materials in printing. It explores various filament manufacturing methods, highlighting extrusion The main advantages using are discussed, then recycled filaments, their benefits, and difficulties possibilities related applications covered. Next, filaments aerospace, automotive, medical, electronics, prosthetics/orthotics explored. Finally, discusses current challenges suggests future directions for research.

Language: Английский

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