Investigation of Mechanical Recycling for Polylactic Acid filaments in Fused Filament Fabrication

The increasing use of additive manufacturing, commonly referred to as 3D printing, has brought notable progress across various sectors. However, this growth has also raised concerns about material waste and environmental sustainability. Polylactic acid (PLA), a biodegradable thermoplastic polymer derived from renewable resources, is among the most frequently utilized materials in 3D printing. Despite being derived from sustainable sources, the accumulation of PLA waste from unsuccessful prints, support structures, and leftover filament poses a significant challenge to sustainable manufacturing practices. This thesis aims to explore the potential for recycling PLA waste into re-usable filaments for Fused Filament Fabrication. The research focuses on evaluating the mechanical and thermal properties, as well as the dimensional accuracy of printed components made from recycled PLA in comparison with those from virgin PLA. A structured approach was developed for gathering, shredding, and re-extruding PLA waste into new filament. Additionally, the effects of multiple recycling cycles on material properties were analysed to understand the eventual long-term viability of using recycled PLA in manufacturing.