3D printing, one of the fastest developing technologies, can change the manufacturing process and many other consumer goods markets. This research describes the approach of developing a sustainable smartphone case cover from polylactic acid (PLA) and wood-based material using 3D printing technology with optimized parameters. We also suggested reverse logistics for recycling the phone case covers, which helped extend the product life cycle. The foundation of this research is in the crown of strong consumer service and communication to address appropriate feedback and consumers’ concerns, thus highlighting consumer satisfaction and retention. In addition, factors such as cost, production timelines, transport systems, and product returns are given particular attention, emphasizing the incorporation of buy-back programs and reverse logistics into the plan for bettering product quality and increasing longevity. The study combines research and empirical studies to examine product manufacturing and reverse logistics in the context of India. We employed a mixed-method approach, conducting online and face-to-face consumer surveys and interviews with smartphone users to gather insights into their behaviors, attitudes, and preferences regarding biodegradable phone cases. Results show how consumer perceptions influence the adoption of this technology in a reverse logistics framework and help improve quality through sustainable manufacturing. The study suggests that combining sustainable design, customer engagement, and effective reverse logistics enhances the circular economy, promotes responsible consumption, and manages the operational excellence of product returns.