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<p>Most prior studies in the field of Distributed Recycling Additive Manufacturing (DRAM) have focused on utilizing recycle-bots—waste plastic extruders—to produce feedstock for Fused Filament Fabrication (FFF). This work introduces and rigorously assesses an innovative, energy-efficient recycling technique specifically developed for post-consumer PET sourced from water bottles, bypassing conventional extrusion-based filament production. The proposed approach enables the direct fabrication of high-quality PET filament, with comprehensive material characterization performed at each stage: raw material, filament, and 3D-printed specimens. Results indicate that the recycling process effectively preserves the semi-crystalline nature of PET (approximately 30% crystallinity) and maintains a high glass transition temperature (75–82&#xa0;°C), while significantly minimizing thermal degradation. Key FFF process parameters—including infill density, printing speed, and layer thickness—were systematically optimized using the Taguchi method coupled with Grey Relational Analysis (GRA), aiming to simultaneously maximize mechanical performance (Young’s modulus and tensile strength) and minimize production time and material consumption. Under optimized conditions, virgin PET exhibited a Young’s modulus of 3670&#xa0;MPa and a tensile strength of 45&#xa0;MPa, while recycled PET achieved 2311&#xa0;MPa and 30&#xa0;MPa, respectively. Despite the performance gap—attributed primarily to partial crystallinity loss during reprocessing—the mechanical properties of recycled PET remain competitive with those of commonly used thermoplastics, such as PLA. Furthermore, the low prediction errors (&lt; 5%) between experimental and GRA-forecasted responses confirm the robustness of the adopted multi-objective optimization framework. This study underscores the viability of using directly recycled PET as a sustainable and efficient alternative material in FFF, offering both environmental and functional benefits for structural applications.</p> Graphical abstract <p></p>

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Parametric optimization and modeling of fused filament fabrication (FFF) using recycled PET from water bottles: a comparative study with virgin PET

  • 期刊论文

  • 发表日期：

    2025年10月10日

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  • Rania Ben Amor,
  • Slim Souissi,
  • Ahmed Elloumi,
  • Hatem Bentaher

摘要

Most prior studies in the field of Distributed Recycling Additive Manufacturing (DRAM) have focused on utilizing recycle-bots—waste plastic extruders—to produce feedstock for Fused Filament Fabrication (FFF). This work introduces and rigorously assesses an innovative, energy-efficient recycling technique specifically developed for post-consumer PET sourced from water bottles, bypassing conventional extrusion-based filament production. The proposed approach enables the direct fabrication of high-quality PET filament, with comprehensive material characterization performed at each stage: raw material, filament, and 3D-printed specimens. Results indicate that the recycling process effectively preserves the semi-crystalline nature of PET (approximately 30% crystallinity) and maintains a high glass transition temperature (75–82 °C), while significantly minimizing thermal degradation. Key FFF process parameters—including infill density, printing speed, and layer thickness—were systematically optimized using the Taguchi method coupled with Grey Relational Analysis (GRA), aiming to simultaneously maximize mechanical performance (Young’s modulus and tensile strength) and minimize production time and material consumption. Under optimized conditions, virgin PET exhibited a Young’s modulus of 3670 MPa and a tensile strength of 45 MPa, while recycled PET achieved 2311 MPa and 30 MPa, respectively. Despite the performance gap—attributed primarily to partial crystallinity loss during reprocessing—the mechanical properties of recycled PET remain competitive with those of commonly used thermoplastics, such as PLA. Furthermore, the low prediction errors (< 5%) between experimental and GRA-forecasted responses confirm the robustness of the adopted multi-objective optimization framework. This study underscores the viability of using directly recycled PET as a sustainable and efficient alternative material in FFF, offering both environmental and functional benefits for structural applications.

Graphical abstract