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<p>Additive manufacturing (AM), particularly 3D printing, has revolutionized numerous industries by enabling rapid prototyping and highly customizable production. However, its growing prevalence has led to significant accumulation of polymer-based waste, primarily from polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). This review provides a critical assessment of current recycling approaches—mechanical, chemical, and thermal decomposition—focusing on key metrics, including energy requirements, material recovery efficiency, contamination resilience, output quality, and industrial applicability. Mechanical recycling is notably energy-efficient (approximately 2.5&#xa0;MJ/kg), but its effectiveness is hindered by polymer degradation and limited tolerance for mixed or contaminated waste streams. Chemical recycling, while capable of achieving high recovery rates (up to 90%) and superior output quality, demands substantial energy (~ 7.8&#xa0;MJ/kg) and specialized infrastructure, making it economically and technically challenging. Thermal decomposition methods such as pyrolysis can process heavily contaminated waste but lack circularity, as the resulting products are predominantly fuels. The review also examines emerging technologies, including enzymatic depolymerization, AI-driven sorting systems, and advanced upcycling techniques, evaluating their scalability, cost-effectiveness, and technology readiness levels (TRLs 4–7). Comparative benchmarking tables, life cycle assessment (LCA) data, and case studies from industries including aerospace and automotive illustrate the practical viability of these innovations. In conclusion, the review outlines strategic pathways for advancing sustainable additive manufacturing. These include the development of closed-loop recycling systems, the design of biodegradable additives, the implementation of extended producer responsibility (EPR), and the use of policy-driven incentives to promote circularity in 3D printing. Collectively, these measures aim to improve environmental outcomes while aligning with the technical and economic demands of industrial adoption.</p>

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Innovative approaches to recycling and waste reduction in 3D printing

  • 期刊论文

  • 发表日期：

    2025年8月22日

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  • V. Phutela,
  • S. Juneja

摘要

Additive manufacturing (AM), particularly 3D printing, has revolutionized numerous industries by enabling rapid prototyping and highly customizable production. However, its growing prevalence has led to significant accumulation of polymer-based waste, primarily from polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). This review provides a critical assessment of current recycling approaches—mechanical, chemical, and thermal decomposition—focusing on key metrics, including energy requirements, material recovery efficiency, contamination resilience, output quality, and industrial applicability. Mechanical recycling is notably energy-efficient (approximately 2.5 MJ/kg), but its effectiveness is hindered by polymer degradation and limited tolerance for mixed or contaminated waste streams. Chemical recycling, while capable of achieving high recovery rates (up to 90%) and superior output quality, demands substantial energy (~ 7.8 MJ/kg) and specialized infrastructure, making it economically and technically challenging. Thermal decomposition methods such as pyrolysis can process heavily contaminated waste but lack circularity, as the resulting products are predominantly fuels. The review also examines emerging technologies, including enzymatic depolymerization, AI-driven sorting systems, and advanced upcycling techniques, evaluating their scalability, cost-effectiveness, and technology readiness levels (TRLs 4–7). Comparative benchmarking tables, life cycle assessment (LCA) data, and case studies from industries including aerospace and automotive illustrate the practical viability of these innovations. In conclusion, the review outlines strategic pathways for advancing sustainable additive manufacturing. These include the development of closed-loop recycling systems, the design of biodegradable additives, the implementation of extended producer responsibility (EPR), and the use of policy-driven incentives to promote circularity in 3D printing. Collectively, these measures aim to improve environmental outcomes while aligning with the technical and economic demands of industrial adoption.