Process Parameters and Manufacturing defects for Large Scale Additive Manufacturing using Recycled Polymer Pellets

Large-scale additive manufacturing offers promising potential for design industries with its mold-free production, geometric freedom, and mass customization capabilities. However, using polymers in large-scale printing poses environmental challenges due to plastic waste. To address this, research on recycled polymers is crucial, but literature on the topic is limited. This paper investigates optimal process parameters and design guidelines for large-scale additive manufacturing using recycled polymer pellets. It addresses the lack of information in the literature and explores three recycled polymers which are not currently recycled by the industry: rPLA, rHDPE, and rABS. Key process parameters include temperature, layer height, feed, and extruder speed. Design recommendations include strategies to mitigate issues like warping, poor adhesion, and moisture content. By incorporating recycled polymers, the design industry can reduce its environmental impact and enhance manufacturing efficiency.