Toward High-Value Circular Pathways for Polymer Waste: Process–Structure–Property Strategies in Mechanical Recycling, Filament Re-Extrusion, and Additive Manufacturing

The global polymer waste burden has catalyzed a shift from linear “production–use–disposal” systems to circular models that prioritize recycling, reuse, and value retention. This article proposes an integrated, technology-ready roadmap for mechanical recycling and reuse of commodity and bio-based polymers via filament re-extrusion and Additive Manufacturing (AM). Building upon recent findings on performance envelopes of virgin vs. recycled Polylactic Acid (PLA) filaments processed by Fused Deposition Modeling (FDM), process parameter sensitivities (layer height, infill density) and their statistical optimization, and functional reinforcement routes (aluminum: Al, alumina: Al2O3, titanium: Ti, and Nano Boron Nitride: nano-BN), we articulate (1) a process–structure–property (PSP) mapping; (2) a low-defect, low-energy filament re-extrusion protocol; and (3) a graded-value strategy for upcycling mixed polymer streams. Across case analyses, we show that recycled PLA can achieve near-parity with virgin PLA when extrusion quality and printing parameters are controlled, and that ceramic/metal nanofillers enable thermal management and biocompatibility benefits crucial for durable reuse scenarios.