Plastics : Additive Manufacturing with Recycled Plastics

Simple definition:

Additive Manufacturing with Recycled Plastics is the process of using 3D printing technology to create new products from previously used plastic materials. 

Instead of throwing plastic waste away, it gets processed into printable filament or powder that can be used to make new objects layer by layer.

A more detailed look:

Additive Manufacturing with Recycled Plastics represents a convergence of advanced manufacturing technology and circular economy principles. 

This approach involves collecting post-consumer or post-industrial plastic waste, processing it through mechanical or chemical recycling methods, and converting it into feedstock materials (filaments, pellets, or powders) suitable for 3D printing processes.

The technology enables decentralized, on-demand production where plastic waste can be transformed into functional products at or near the point of consumption, reducing transportation costs and environmental impact. 

This process typically involves shredding, cleaning, melting, and extruding waste plastics into consistent diameter filaments or other printable forms while maintaining material properties suitable for additive manufacturing.

Key opportunities:

Localized recycling:

• Communities can process their own plastic waste locally rather than shipping it to distant recycling facilities
• Reduces transportation emissions and costs
• Creates local economic opportunities and jobs
• Enables faster response to local material needs

Customized production:

• On-demand manufacturing reduces inventory waste
• Products can be tailored to specific user needs
• Rapid prototyping and iteration capabilities
• Mass customization becomes economically viable

Examples:

Consumer products:

• Precious plastic: a global community project that provides open-source machines and knowledge for turning plastic waste into new products using small-scale 3D printing and injection molding
• Adidas parley shoes: using ocean plastic waste to create 3D-printed midsoles for athletic footwear

Industrial applications:

• Automotive parts: Ford and BMW use recycled plastic filaments to 3D print prototypes and low-volume production parts
• Construction materials: companies like WASP create 3D-printed building components using recycled plastic mixed with natural fibers

Medical applications:

• Recycled surgical instruments: some medical device companies are experimenting with 3D-printed single-use instruments from recycled medical-grade plastics

Educational and community projects:

• Plastic bank: collects ocean-bound plastic in developing countries and converts it into 3D printing filament for local manufacturing of school supplies and household items
• Fab labs worldwide: community makerspaces that teach people to turn local plastic waste into useful objects through 3D printing

Packaging and logistics:

• UPS and other logistics companies: create custom packaging solutions on-demand using recycled plastic, reducing storage needs and waste
• Amazon: experimenting with 3D-printed packaging made from returned product packaging materials

This technology is particularly promising because it addresses multiple challenges simultaneously: 

• Plastic waste reduction 
• Manufacturing sustainability 
• Supply chain resilience
• Economic development in underserved communities.