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

Mohammad Raquibul Hasan, Ian J. Davies, Alokesh Pramanik, Michele John and Wahidul K. Biswas ()
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Mohammad Raquibul Hasan: Sustainable Engineering Group, School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia
Ian J. Davies: School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia
Alokesh Pramanik: School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia
Michele John: Sustainable Engineering Group, School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia
Wahidul K. Biswas: Sustainable Engineering Group, School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia

Sustainability, 2025, vol. 17, issue 6, 1-26

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

Keywords: additive manufacturing; blend PLA; fused deposition modelling; mechanical properties; recycled PLA (rPLA); virgin PLA (vPLA); waste plastic (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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