Table 3.
Summary of research work on developing recycled composite filament
| S. no. | Plastic waste | Filament composition | Extruder type | Filament diameter (mm) | 3D printer | TS (MPa) | Purpose of using additives | Findings | Refs. |
|---|---|---|---|---|---|---|---|---|---|
| 1. | PLA | V-PLA/ R-PLA | Single screw | – | Pramaan mini | 37.829 | Upgrading the properties of the recycled polymer | Maximum TS with 10% R-PLA | [68] |
| 2. |
HDPE PP |
R-HDPE/R-PP/soy hull Biocarbon (size: 2 µm) | Twin screw | 1.75 | Lulzbot Taz 6 | 38–40 | Developing cost-effective composite enhances the analytical properties and develops lightweight composites | Addition of biochar creates porous structure and lightweight material (spectacle frame, elliptical gears) | [70] |
| 3. |
HDPE PP |
o-HDPE/o-PP/V-HDPE/V-LDPE/clay/EPR | 3-Devo 350 Composer | 1.75 | Creality 3-D printer | 21.4 ± 0.9 | Improving the compatibility among immiscible blends | Addition of EPR increased elasticity of material | [71] |
| 4. | Expanded PS | R-PS/LDPE | Single screw | 1.5–1.75 | Creality Ender-3 V2 | 25–30 | Enhancing the printability and thermal stability of final material | TS decreased with increase in ductility | [117] |
| 5. |
PET PP PS |
R-PET/R-PP/R-PS/SEBS-MA | Twin screw | 1.75 | Lulzbot Taz 6 | 24.2 ± 1 | Making a flexible filament that can easily be 3D printed | Elongation at failure improved for all blends | [109] |
| 6. | TPU | TPU/PUF particles | Felfil Evo Colours | 1.5 | Anycubic Chiron | 10.8 ± 0.8 | Making of cost-effective composite and final material to be processed at higher temperature | TS decreased by 68.32% | [73] |
| 7. |
Nylon Polyester |
R-nylon/R-polyester/photopolymer resin (size: nylon powder 15–20 µm) | Not required | - | Form 1+, Formlabs Inc | 14 (resin–5%polyester) | Enhancing the tribological properties |
TS decreased by 26.31% Wear rate improved by 9.4 times |
[74] |
| 8. | PLA | V-PLA/ R-PLA/MCC/J | Twin screw | 2.2 | – |
44 (PLA/R-PLA) 20 (PLA/R-PLA/0.5 J) |
Controlling the rheological properties (like MFI) of the final material | Stiffness improved by 88% | [69] |
| 9. | ABS | ABS/recycled Bakelite/Al2O3/SiC particles (size of SiC/Al2O3 and Bakelite particle: 20 µm) | Twin screw | 1.75 | Accucraft i250+ | 14–16 (70%ABS–10%BAK–10%Al2O3–10%SiC) |
1. Enhancing the tensile strength by adding Bakelite 2. Enhancing the wear resistance properties by adding ceramic (like Al2O3 and SiC) with BAK |
Uniform dispersion with 60% infill ratios and 50 mm/s printing speed | [10] |
| 10. | 2° R-ABS |
R-ABS/bakelite powder/wood dust (WD) Particle size: wood dust: 50 µm; BP size was similar to that of WD |
Twin-screw extruder | NA | – |
30.82 ± 1.7 (90% ABS + 10% BP) 25.66 ± 1.4 (90% ABS + 10% WD) |
Providing a good thermal interlocking bonding among the polymer particles and enhancing the thermal conductivity of the final material | Less porosity noticed | [9] |
| 11. | PET | White cotton extracted from denim | Single screw | 1.75 ± 0.15 | Prusa i3 | NA |
1. Providing high specific strength and low density to the final material 2. Enhancing the dampening capacity of material |
Impact strength of R-PET-WC increased by 63.87% | [15] |
| 12. | Shredded flakes of HDPE | HDPE/LLDPE/di-methyl-di-benzylidene sorbitol (DMDBS) | Home built | 1.68–1.72 | Julia + | NA |
1. LLDPE was added for reducing part warpage during 3D printing 2. DMDBS was added for increasing the melt stiffness of final material |
Incorporating brim improved the adhesion of printed object to the substrate | [118] |
| 13. | HDPE | HDPE/ ZrO2 (size: 15 µm) | Twin Screw | 1.75 ± 0.05 | Not required | 17.22 ± 0.34 | Reducing the coefficient of friction, resisting wear environment and improving the tensile strength of material | HDPE with 40% ZrO2 shown better mechanical properties | [11] |
| 14. | HDPE | HDPE/SiC/Al2O3 (size of SiC/Al2O3 particle: 20 µm) | Single screw | NA | Not required | 23.87 | Combination of Al2O3 and SiC as filler was chosen for reducing the cost factor and increasing the wear-resistant properties of the final material | – | [13] |
| 15. | LDPE | LDPE/SiC/Al2O3 (size of SiC/Al2O3 particle: 20 µm) | Twin screw | 1.75 ± 0.05 | Not required | 679.38 | Combination of Al2O3 and SiC as filler was chosen to reduce the cost factor and increase the wear-resistant properties of the final material | Addition of SiC/Al2O3 increased TS by 6.79% | [12] |
| 16. | 2° R-ABS | R-ABS/Gr (size: 5–10 nm) | Twin Screw | 2 ± 0.02 | FFF printer | 43.48 |
1. Preventing polymer from environmental degradation 2. Enhancing the rheological, thermal, magneto metric and mechanical properties of the final composite |
Thermal heat capacity increased by 413% | [83] |
| 17. | 2° R-ABS | R-ABS/Gr (size: 5–10 nm) | Twin Screw | 1.75 | Open-source printer | 36.75 | Upgrading the functionality of recycled material | Porosity decreased by 4.93% | [82] |
| 18. | R-plastic | V-PLA/V-HDPE/recycled plastic/TiO2 nanoparticle (size: 10–50 nm) | Twin screw | 1.72–1.77 | FFF printer | 17.5 |
1. Graphene is used for creating a hydrophobic coating of 3D printed specimens 2. TiO2 was used for enhancing the interlaminar properties of the final product |
Graphene-coated specimens showed good surface profile | [75] |
| 19. | PP | r-PP/rice husk (size: 250 and 425 µm) | Twin screw | 1.75 ± 0.05 | Magigoo 3D printer |
13.78 ± 0.59 (at 0° raster) 7.92 ± 0.67 (at 90° raster) |
1. Making lightweight parts like customized jigs and fixture and thermoformed parts at minimal cost 2. Effectively using agricultural waste |
TS reduced by 47.04% | [76] |
| 20. | PP | r-PP/hemp short fiber | Twin screw | 3 | FFF printer | 22.45 | Reducing the shrinkage tendency of polymer matrix | TS enhanced by 31.90% | [77] |
| r-PP/harakeke short fiber | 23.55 | TS enhanced by 38.37% | |||||||
| r-PP/r-gypsum powder | 24.09 | TS enhanced by 7% | |||||||
| 21. | PP | r-PP/basalt short fiber (size: Lavg. = 4.5 mm and davg. = 16 µm) | Single screw | 1.37 | Not required | 35.5 | Improving the tensile strength and elastic modulus of recycled composite | TS increased by 23.08% | [78] |
| 22. | PP | r-PP/short CF (size: Lavg = 200 µm and davg. = 70 µm) | Single screw | – | Ultimaker S3 |
22.70 (composite filament) 19.72 (3D printed composite) |
1. Developing high-quality recycled feedstock filament with good mechanical strength |
1. TS of filament increased by 10.99% 2. TS of 3D printed specimen decreased by 6.27% |
[79] |
| 23. | R-PET | Biochar (size below 100 µm) | Filabot extruder | 1.75 ± 0.03 | Hyrel30M | 51.87 (PET/0.5 wt% Biochar) | 2. Improving the thermo-mechanical performance of 3D printed composite | TS improved by 32% | [14] |
| 24. | HDPE/LDPE | R-HDPE R-LDPE/Fe powder (size: 54 µm) | Single screw | 1.70–1.8 | – |
8–12 (HDPE-10 wt% Fe powder) 6–7.5 (LDPE-6 wt% Fe powder) |
1. Making composite conductive in nature 2. Making composite a suitable candidate for non-destructive testing (NDT) 3. Enhancing the mechanical properties of the final product |
– | [80] |
| 25. | 2° ABS | R-ABS/Fe powder (size: 50 µm) | Twin screw | – | Not required | 32.72 ± 1.5 | Enhancing the thermal and mechanical properties | MFI increased by 25.29% | [81] |
| 26. | PP | R-PP/CBS (size: 250–425 µm) | Twin screw | 1.75 ± 0.1 | 3D FF-STD Doppia | 15.23 ± 0.91 | Enabling the effective utilization of waste obtained from consumable products | TS reduced by 41.47% | [85] |
| 27. | PP | R-PP/Tire microparticles | Twin screw | – | Robot Yaskawa Motoman HP20F (modified) | 6.0 | Fabricating big green part with free and desired geometries | Melting temperature of composite increased by 2.55% | [84] |