Sustainable design approaches for thermoplastics in additive manufacturing

Additive manufacturing is enabling on-demand fabrication of desirable polymer designs. Due to the technology’s widespread use, there is a need to ensure sustainable design approaches are practiced. Here, thermoplastics for fused deposition modeling is reviewed for life-cycle stages, mechanical properties, and design strategies. Life-cycle stages assessed include formulation, processing, applications, and end-of-life as well as recycling processes. Mechanical properties are considered for recyclable thermoplastics, with fillers to enhance functionality. Finally, design methods are considered to create mechanically efficient designs, such as metamaterials, that reduce material usage and processing time. The review highlights the great potential for creating sustainable designs with additively manufactured polymers, and their mechanical capabilities for broad applications.