Realization of Circular Economy of 3D Printed Plastics: A Review

Evaluation of the Viability of 3D Printing in Recycling Polymers

The increased use of plastics in industrial and agricultural applications has led to high levels of pollution worldwide and is a significant challenge. To address this plastic pollution, conventional methods such as landfills and incineration are used, leading to further challenges such as the generation of greenhouse gas emissions. Therefore, increasing interest has been directed to identifying alternative methods to dispose of plastic waste from agriculture. The novelty of the current research arose from the lack of critical reviews on how 3-Dimensional (3D) printing was adopted for recycling plastics, its application in the production of agricultural plastics, and its specific benefits, disadvantages, and limitations in recycling plastics. The review paper offers novel insights regarding the application of 3D printing methods including Fused Particle Fabrication (FPF), Hot Melt Extrusion (HME), and Fused Deposition Modelling (FDM) to make filaments from plastics. However, the methods were adopted in local recycling setups where only small quantities of the raw materials were considered. Data was collected using a systematic review involving 39 studies. Findings showed that the application of the 3D printing methods led to the generation of agricultural plastics such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate (PET), and High-Density Polyethylene (HDPE), which were found to have properties comparable to those of virgin plastic, suggesting the viability of 3D printing in managing plastic pollution. However, limitations were also associated with the 3D printing methods; 3D-printed plastics deteriorated rapidly under Ultraviolet (UV) light and are non-biodegradable, posing further risks of plastic pollution. However, UV stabilization helps reduce plastic deterioration, thus increasing longevity and reducing disposal. Future directions emphasize identifying methods to reduce the deterioration of 3D-printed agricultural plastics and increasing their longevity in addition to UV stability.

Turning plastics/microplastics into valuable resources? Current and potential research for future applications

Plastics are a wide range of synthetic or semi-synthetic materials, mainly consisting of polymers. The use of plastics has increased to over 300 million metric tonnes in recent years, and by 2050, it is expected to grow to 800 million. Presently, a mere 10% of plastic waste is recycled, with approximately 75% ended up in landfills. Inappropriate disposal of plastic waste into the environment poses a threat to human lives and marine species. Therefore, this review article highlights potential routes for converting plastic/microplastic waste into valuable resources to promote a greener and more sustainable environment. The literature review revealed that plastics/microplastics (P/MP) could be recycled or upcycled into various products or materials via several innovative processes. For example, P/MP are recycled and utilized as anodes in lithium-ion (Li-ion) and sodium-ion (Na-ion) batteries. The anode in Na-ion batteries comprising PP carbon powder exhibits a high reversible capacity of ∼340 mAh/g at 0.01 A/g current state. In contrast, integrating Fe3O4 and PE into a Li-ion battery yielded an excellent capacity of 1123 mAh/g at 0.5 A/g current state. Additionally, recycled Nylon displayed high physical and mechanical properties necessary for excellent application as 3D printing material. Induction heating is considered a revolutionary pyrolysis technique with improved yield, efficiency, and lower energy utilization. Overall, P/MPs are highlighted as abundant resources for the sustainable production of valuable products and materials such as batteries, nanomaterials, graphene, and membranes for future applications.

Surface Evaluation of Gyroid Structures for Manufacturing Rubber-Textile Conveyor Belt Carcasses Using Micro-CT

Gyroid structures are among the most widely used three-dimensional elements produced by various additive manufacturing technologies. This paper focuses on a metrological analysis of Flexfill 92A material specimens with a relative density (25 to 85%) using industrial computer tomography. The results show that for a given structure, the best method is to use surface determination with the closure of internal defects in the material. The analysis implies that the smallest deviations of the specimens' external dimensions were achieved with respect to the CAD model at the highest relative densities. The wall thickness shows the smallest percentage change of 0.5685 at 45% relative density and the largest at 25% and 85% relative density. The nominal-actual comparison of manufactured specimens to the CAD model shows the smallest cumulative deviation of 0.209 mm at 90% and 25% relative density, while it slightly increases with increasing relative density. All produced specimens have a smaller material volume than their theoretical volume value, while the percentage change in volume is up to 8.6%. The surface of specimens is larger compared with the theoretical values and the percentage change reaches up to 25.3%. The percentage of pores in the specimens increases with increasing relative density and reaches 6%. The acquired knowledge will be applied in the framework of research focused on the possibilities of using additive manufacturing to produce a skeleton of rubber-textile conveyor belts. This paper presents initial research on the possibility of replacing the carcass of rubber-textile belts with an additive technology use.

Recycled PLA for 3D Printing: A Comparison of Recycled PLA Filaments from Waste of Different Origins after Repeated Cycles of Extrusion

The objective of this work is to evaluate the reprocessing of PLA 3D printing waste from different origins, into filaments and films, and without the addition of any additive. Two types of waste were considered: a blend of different printing wastes (masks, visors, other components) of personal protective equipment coming from an association of Spanish coronamakers, and PLA waste from a single known commercial source. Both types of materials were subjected to repeated extrusion cycles and processed into films by compression molding. Samples were characterized after each cycle and their mechanical and viscosity properties evaluated. Diffusion-ordered NMR spectroscopy (DOSY) experiments were also carried out to estimate molecular weights. The results show a better performance for the PLA waste from the known origin, capable of withstanding up to three re-extrusion cycles per two for the waste blending, without significant degradation. Additionally, a model to address collection and mechanical recycling cycles under two different scenarios (full traceability and not full traceability) was proposed.

Three-Dimensional Printing of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) [P(3HB-co-3HV)] Biodegradable Scaffolds: Properties, In Vitro and In Vivo Evaluation

The results of constructing 3D scaffolds from degradable poly(3-hydrosbutyrpate-co-3-hydroxyvalerate) using FDM technology and studying the structure, mechanical properties, biocompatibility in vitro, and osteoplastic properties in vivo are presented. In the process of obtaining granules, filaments, and scaffolds from the initial polymer material, a slight change in the crystallization and glass transition temperature and a noticeable decrease in molecular weight (by 40%) were registered. During the compression test, depending on the direction of load application (parallel or perpendicular to the layers of the scaffold), the 3D scaffolds had a Young's modulus of 207.52 ± 19.12 and 241.34 ± 7.62 MPa and compressive stress tensile strength of 19.45 ± 2.10 and 22.43 ± 1.89 MPa, respectively. SEM, fluorescent staining with DAPI, and calorimetric MTT tests showed the high biological compatibility of scaffolds and active colonization by NIH 3T3 fibroblasts, which retained their metabolic activity for a long time (up to 10 days). The osteoplastic properties of the 3D scaffolds were studied in the segmental osteotomy test on a model defect in the diaphyseal zone of the femur in domestic Landrace pigs. X-ray and histological analysis confirmed the formation of fully mature bone tissue and complete restoration of the defect in 150 days of observation. The results allow us to conclude that the constructed resorbable 3D scaffolds are promising for bone grafting.

Optimizing the Rheological and Thermal Behavior of Polypropylene-Based Composites for Material Extrusion Additive Manufacturing Processes

In this study, composites based on a heterophasic polypropylene (PP) copolymer containing different loadings of micro-sized (i.e., talc, calcium carbonate, and silica) and nano-sized (i.e., a nanoclay) fillers were formulated via melt compounding to obtain PP-based materials suitable for Material Extrusion (MEX) additive manufacturing processing. The assessment of the thermal properties and the rheological behavior of the produced materials allowed us to disclose the relationships between the influence of the embedded fillers and the fundamental characteristics of the materials affecting their MEX processability. In particular, composites containing 30 wt% of talc or calcium carbonate and 3 wt% of nanoclay showed the best combination of thermal and rheological properties and were selected for 3D printing processing. The evaluation of the morphology of the filaments and the 3D-printed samples demonstrated that the introduction of different fillers affects their surface quality as well as the adhesion between subsequently deposited layers. Finally, the tensile properties of 3D-printed specimens were assessed; the obtained results showed that modulable mechanical properties can be achieved depending on the type of the embedded filler, opening new perspectives towards the full exploitation of MEX processing in the production of printed parts endowed with desirable characteristics and functionalities.

Drug Delivery Systems in Regenerative Medicine: An Updated Review

Modern drug discovery methods led to evolving new agents with significant therapeutic potential. However, their properties, such as solubility and administration-related challenges, may hinder their benefits. Moreover, advances in biotechnology resulted in the development of a new generation of molecules with a short half-life that necessitates frequent administration. In this context, controlled release systems are required to enhance treatment efficacy and improve patient compliance. Innovative drug delivery systems are promising tools that protect therapeutic proteins and peptides against proteolytic degradation where controlled delivery is achievable. The present review provides an overview of different approaches used for drug delivery.

Repurposing of waste PET by microbial biotransformation to functionalized materials for additive manufacturing

Plastic waste is an outstanding environmental thread. Poly(ethylene terephthalate) (PET) is one of the most abundantly produced single-use plastics worldwide, but its recycling rates are low. In parallel, additive manufacturing is a rapidly evolving technology with wide-ranging applications. Thus, there is a need for a broad spectrum of polymers to meet the demands of this growing industry and address post-use waste materials. This perspective article highlights the potential of designing microbial cell factories to upcycle PET into functionalized chemical building blocks for additive manufacturing. We present the leveraging of PET hydrolyzing enzymes and rewiring the bacterial C2 and aromatic catabolic pathways to obtain high-value chemicals and polymers. Since PET mechanical recycling back to original materials is cost-prohibitive, the biochemical technology is a viable alternative to upcycle PET into novel 3D printing materials, such as replacements for acrylonitrile butadiene styrene. The presented hybrid chemo-bio approaches potentially enable the manufacturing of environmentally friendly degradable or higher-value high-performance polymers and composites and their reuse for a circular economy.

ONE-SENTENCE SUMMARY

Biotransformation of waste PET to high-value platform chemicals for additive manufacturing.

Three-Dimensional Printing in Neurosurgery: A Review of Current Indications and Applications and a Basic Methodology for Creating a Three-Dimensional Printed Model for the Neurosurgical Practice

Introduction Three-dimensional (3D) printing is an affordable aid that is useful in neurosurgery. It allows for better visualization and tactile appreciation of the individual anatomy and regions of interest and therefore potentially lowers the risk of complications. There are various applications of this technology in the field of neurosurgery. Materials and methods In this paper, we present a basic methodology for the creation of a 3D printed model using only open-source software for medical image editing, model generation, pre-printing preparation, and analysis of the literature concerning the practical use of this methodology. Results The literature review on the current applications of 3D printed models in neurosurgery shows that they are mostly used for preoperative planning, surgical training, and simulation, closely followed by their use in patient-specific implants and instrumentation and medical education. Materialise^TM Mimics is the most frequently used commercial software for a 3D modeling for preoperative planning and surgical simulation, while the most popular open-source software for the same applications is 3D Slicer. In this paper, we present the algorithm that we employ for 3D printing using Horos^TM, Blender, and Cura software packages which are all free and open-source. Conclusion Three-dimensional printing is becoming widely available and of significance to neurosurgical practice. Currently, there are various applications of this technology that are less demanding in terms of technical knowledge and required fluency in medical imaging software. These predispositions open the field for further research on the possible use of 3D printing in neurosurgery.

Bonding and Strengthening the PLA Biopolymer in Multi-Material Additive Manufacturing

3D printing is a revolutionary additive manufacturing method that enables rapid prototyping and design flexibility. A variety of thermoplastic polymers can be used in printing. As it is necessary to reduce the consumption of petrochemical resources, alternative solutions are being researched, and the interest in using bioplastics and biocomposites is constantly growing. Often, however, the properties of biopolymers are insufficient and need to be improved to compete with petroleum-based plastics. The paper aims to analyze the available information on elements produced from more than one material, with additive manufacturing resulting from 3D printing using biopolymer Polylactic Acid (PLA). The study notes the possibility of modifying and improving the properties of PLA using layered printing or by modifying PLA filaments. Several modifications improving and changing the properties of PLA were also noted, including printing parameters when combined with other materials: process temperatures, filling, and surface development for various sample geometries.

The sustainability of emerging technologies for use in pharmaceutical manufacturing

INTRODUCTION

Sustainability within the pharmaceutical industry is becoming a focal point for many companies, to improve the longevity and social perception of the industry. Both additive manufacturing (AM) and microfluidics (MFs) are continuously progressing, so are far from their optimization in terms of sustainability; hence, it is the aim of this review to highlight potential gaps alongside their beneficial features. Discussed throughout this review also will be an in-depth discussion on the environmental, legal, economic, and social particulars relating to these emerging technologies.

AREAS COVERED

Additive manufacturing (AM) and microfluidics (MFs) are discussed in depth within this review, drawing from up-to-date literature relating to sustainability and circular economies. This applies to both technologies being utilized for therapeutic and analytical purposes within the pharmaceutical industry.

EXPERT OPINION

It is the role of emerging technologies to be at the forefront of promoting a sustainable message by delivering plausible environmental standards whilst maintaining efficacy and economic viability. AM processes are highly customizable, allowing for their optimization in terms of sustainability, from reducing printing time to reducing material usage by removing supports. MFs too are supporting sustainability via reduced material wastage and providing a sustainable means for point of care analysis.

Implementation of Microwave Circuits Using Stereolithography

In this work, the use of additive manufacturing techniques through stereolithography for the manufacture of high-frequency circuits and devices is presented. Both the resin and the 3D printer used in this research are general-purpose commercial materials, not specifically intended for the implementation of microwave networks. The manufacturing and metallization procedures used to produce substrates for the design of planar microwave circuits are described, introducing the characterization process carried out to determine the electrical properties of the resin used. The ultrasonic techniques that allow the structural analysis of the manufactured substrates are also described. The electrical characterization provides a relative dielectric permittivity of 3.25 and a loss tangent of 0.03 for the resin used. In addition, the structural analysis shows a homogeneity and a finish of the manufactured parts that is not achievable using fused deposition modeling techniques. Finally, as a proof of concept, the design and manufacture of a complex geometry stepped impedance filter on a multi-height substrate using stereolithography techniques is presented, which allows for reducing the size of the traditional implementation of the same filter while maintaining its high-frequency response performance.

ABS/Silicon Dioxide Micro Particulate Composite from 3D Printing Polymeric Waste

In this paper, Acrylonitrile-Butadiene-Styrene matrix composites reinforced with Nano-silica dioxide particles were examined and prepared to study their mechanical properties. The composite sheets were pre-prepared using the hot extrusion process. Due to its wide characteristics, silica dioxide additions can strengthen the usability and mechanical features of composite thermoplastics and polymers. Furthermore, introducing silica dioxide as a filler in various attributes can help to maintain the smooth flow of sufficient powders, reduce caking, and manage viscoelasticity. Despite its advantages, 3D printing generates a significant amount of waste due to limited prints or destroyed support structures. ABS is an ideal material to use because it is a thermoplastic and amorphous polymer with outstanding thermal properties that is also applicable with the FFF (Fused Filament Fabrication) technique. The findings showed that increasing the silica dioxide content reduces the tensile strength to 22.4 MPa at 10 wt%. Toughness, ductility, and yield stress values of ABS/silica dioxide composites at 15 wt% increased, indicating that the composite material reinforced by the silica dioxide particles improved material characteristics. It is essential to consider the impact of recycling in polymer reinforcement with fillers. Furthermore, the improved mechanical qualities of the composite material encourages successful ABS recycling from 3D printing, as well as the possibility of reusing it in a similar application.

Dimensional Stability of 3D Printed Objects Made from Plastic Waste Using FDM: Potential Construction Applications

Construction projects are often challenged by tight budgets and limited time and resources. Contractors are, therefore, looking for ways to become competitive by improving efficiency and using cost-effective materials. Using three-dimensional (3D) printing for shaping materials to produce cost-effective construction elements is becoming a feasible option to make contractors more competitive locally and globally. The process capabilities for 3D printers and related devices have been tightened in recent years with the booming of 3D printing industries and applications. Contractors are attempting to improve production skills to satisfy firm specifications and standards, while attempting to have costs within competitive ranges. The aim of this research is to investigate and test the production process capability (Cp) of 3D printers using fused deposition modeling (FDM) to manufacture 3D printed parts made from plastic waste for use in the construction of buildings with different infill structures and internal designs to reduce cost. This was accomplished by calculating the actual requirement capabilities of the 3D printers under consideration. The production capabilities and requirements of FDM printers are first examined to develop instructions and assumptions to assist in deciphering the characteristics of the 3D printers that will be used. Possible applications in construction are then presented. As an essential outcome of this study, it was noticed that the 3D printed parts made from plastic waste using FDM printers are less expensive than using traditional lightweight non-load bearing concrete hollow masonry blocks, hourdi slab hollow bocks, and concrete face bricks.

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

Additive manufacturing (AM) or 3D printing is a digital manufacturing process and offers virtually limitless opportunities to develop structures/objects by tailoring material composition, processing conditions, and geometry technically at every point in an object. In this review, we present three different early adopted, however, widely used, polymer-based 3D printing processes; fused deposition modelling (FDM), selective laser sintering (SLS), and stereolithography (SLA) to create polymeric parts. The main aim of this review is to offer a comparative overview by correlating polymer material-process-properties for three different 3D printing techniques. Moreover, the advanced material-process requirements towards 4D printing via these print methods taking an example of magneto-active polymers is covered. Overall, this review highlights different aspects of these printing methods and serves as a guide to select a suitable print material and 3D print technique for the targeted polymeric material-based applications and also discusses the implementation practices towards 4D printing of polymer-based systems with a current state-of-the-art approach.

Additive manufacturing of polyhydroxyalkanoates (PHAs) biopolymers: Materials, printing techniques, and applications

Additive manufacturing (AM) is recently imposing as a fast, reliable, and highly flexible solution to process various materials, that range from metals to polymers, to achieve a broad variety of customized end-goods without involving the injection molding process. The employment of biomaterials is of utmost relevance as the environmental footprint of the process and, consequently, of the end-goods is significantly decreased. Additive manufacturing can provide, in particular, an all-in-one platform to fabricate complex-shaped biobased items such as bone implants or biomedical devices, that would be, otherwise, extremely troublesome and costly to achieve. Polyhydroxyalkanoates (PHAs) is an emerging class of biobased and biodegradable polymeric materials achievable by fermentation from bacteria. There are some promising scientific and technical reports on the manufacturing of several commodities in PHAs by additive manufacturing. However, many challenges must still be faced in order to expand further the use of PHAs. In this framework, the present work reviews and classifies the relevant papers focused on the design and development of PHAs for different 3D printing techniques and overviews the most recent applications of this approach.