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<p>The activation of zeolites into recycled polypropylene (r-PP) offers a transformative approach to upcycling plastic waste into sustainable composite materials for 3d printing and injection molding, addressing challenges in circular economic practices. This study focuses on the impact of varying zeolite concentrations (0&#xa0;wt%, 2&#xa0;wt%, 5&#xa0;wt%, 10&#xa0;wt%, 20&#xa0;wt%, and 30&#xa0;wt%) on material extrusion, filament quality, and mechanical and thermal properties in 3D-printed and injection-molded samples. Optimized extrusion parameters enabled the successful production of filaments, while optical and scanning electron microscopy revealed insights into inter-bead voids, debonding, fibre dispersion, fracture modes, and filament/sample quality. Differential scanning calorimetry and thermogravimetric analysis highlighted modest reductions in melting and crystallization temperatures attributed to slight matrix deterioration. The mechanical performance was evaluated through tensile and flexural testing. 3D-printed specimens exhibited peak tensile strength at 29.25 ± 0.5&#xa0;MPa and flexural strength at 39.21 ± 0.5&#xa0;MPa with 10&#xa0;wt% zeolite, while injection-molded samples achieved superior tensile and flexural strengths of 34.29 ± 0.5&#xa0;MPa and 43.32 ± 0.5&#xa0;MPa, respectively. However, higher zeolite content (≥ 20&#xa0;wt%) resulted in agglomeration, void formation, and reduced mechanical integrity. The introduction of polypropylene tape as a bed layer successfully mitigated adhesion and warpage issues during 3d printing, improving print quality and structural integrity. This work introduces a novel approach by integrating zeolites as functional fillers into recycled PP, enabling diverse applications, including automotive, construction, and packaging industries. Furthermore, the use of zeolites contributes to surface quality enhancement, potential VOC suppression, and thermal stability improvements, aligning with circular economy principles. This research not only addresses key limitations of PP in additive manufacturing but also pioneers the upcycling of plastic waste into high-value, multifunctional composites, making it a significant advancement in sustainable polymer processing. </p>

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Circular economy and sustainability innovation: a deep investigation to use recycled propylene with zeolites in 3D printing and injection molding

  • 期刊论文

  • 发表日期：

    2025年5月28日

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  • Pragti Saini,
  • Himadri Chatterjee,
  • Amit Choudhari,
  • Sampat Singh Bhati,
  • Dharm Dutt

摘要

The activation of zeolites into recycled polypropylene (r-PP) offers a transformative approach to upcycling plastic waste into sustainable composite materials for 3d printing and injection molding, addressing challenges in circular economic practices. This study focuses on the impact of varying zeolite concentrations (0 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, and 30 wt%) on material extrusion, filament quality, and mechanical and thermal properties in 3D-printed and injection-molded samples. Optimized extrusion parameters enabled the successful production of filaments, while optical and scanning electron microscopy revealed insights into inter-bead voids, debonding, fibre dispersion, fracture modes, and filament/sample quality. Differential scanning calorimetry and thermogravimetric analysis highlighted modest reductions in melting and crystallization temperatures attributed to slight matrix deterioration. The mechanical performance was evaluated through tensile and flexural testing. 3D-printed specimens exhibited peak tensile strength at 29.25 ± 0.5 MPa and flexural strength at 39.21 ± 0.5 MPa with 10 wt% zeolite, while injection-molded samples achieved superior tensile and flexural strengths of 34.29 ± 0.5 MPa and 43.32 ± 0.5 MPa, respectively. However, higher zeolite content (≥ 20 wt%) resulted in agglomeration, void formation, and reduced mechanical integrity. The introduction of polypropylene tape as a bed layer successfully mitigated adhesion and warpage issues during 3d printing, improving print quality and structural integrity. This work introduces a novel approach by integrating zeolites as functional fillers into recycled PP, enabling diverse applications, including automotive, construction, and packaging industries. Furthermore, the use of zeolites contributes to surface quality enhancement, potential VOC suppression, and thermal stability improvements, aligning with circular economy principles. This research not only addresses key limitations of PP in additive manufacturing but also pioneers the upcycling of plastic waste into high-value, multifunctional composites, making it a significant advancement in sustainable polymer processing.