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<p>This study explores a sustainable method for converting plastic water bottles made from polyethylene terephthalate (PET) into 3D printing filament for Fused Filament Fabrication (FFF) technologies. PET bottles collected from the university campus students were shredded, sieved, and dried at 140&#xa0;°C for 5&#xa0;h to remove moisture and prevent hydrolytic degradation during extrusion. The dried flakes were then extruded into filament using a desktop single-screw extruder, dehumidified for 5&#xa0;h at 65&#xa0;°C, and stored in a polymer-sealed container to preserve material quality. To identify optimal printing conditions, a custom temperature tower and speed tower were printed to determine the ideal nozzle temperature and print speed for recycled PET (rPET). Standardized ASTM mechanical test specimens for tensile, three-point bending, and compression testing were then printed using the optimized parameters of 270&#xa0;°C and 40&#xa0;mm/s. Mechanical testing of rPET, PLA, and PETG samples was conducted to compare the properties of rPET to these commercially available filaments. It was observed that recycled PET had an ultimate tensile strength approximately 20% lower than that of PLA and PETG, and exhibited ductility 8% and 70% lower than PLA and PETG, respectively. The results showed that while rPET exhibits lower strength and toughness compared to PLA and PETG, it offers moderate stiffness, good ductility, and excellent bending flexibility. These properties make it ideal for prototyping and low-load bearing applications, making it a practical and sustainable alternative to commercial filaments, especially for use in academic settings.</p>

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Recycling plastic water bottles into high quality filaments for sustainable 3D printing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年12月15日

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  • Reem Aly,
  • Shriya Vijay,
  • Vishnu Shyju,
  • Muhammed Sharfuddin,
  • Wael A. Samad

摘要

This study explores a sustainable method for converting plastic water bottles made from polyethylene terephthalate (PET) into 3D printing filament for Fused Filament Fabrication (FFF) technologies. PET bottles collected from the university campus students were shredded, sieved, and dried at 140 °C for 5 h to remove moisture and prevent hydrolytic degradation during extrusion. The dried flakes were then extruded into filament using a desktop single-screw extruder, dehumidified for 5 h at 65 °C, and stored in a polymer-sealed container to preserve material quality. To identify optimal printing conditions, a custom temperature tower and speed tower were printed to determine the ideal nozzle temperature and print speed for recycled PET (rPET). Standardized ASTM mechanical test specimens for tensile, three-point bending, and compression testing were then printed using the optimized parameters of 270 °C and 40 mm/s. Mechanical testing of rPET, PLA, and PETG samples was conducted to compare the properties of rPET to these commercially available filaments. It was observed that recycled PET had an ultimate tensile strength approximately 20% lower than that of PLA and PETG, and exhibited ductility 8% and 70% lower than PLA and PETG, respectively. The results showed that while rPET exhibits lower strength and toughness compared to PLA and PETG, it offers moderate stiffness, good ductility, and excellent bending flexibility. These properties make it ideal for prototyping and low-load bearing applications, making it a practical and sustainable alternative to commercial filaments, especially for use in academic settings.