Sustainability of polycarbonate recycling via additive manufacturing

Nan Yu; Yifan Yuan; Zicheng Zhu; Ruslan Melentiev; Long Ye; James Tinkler; Lukas Raddatz; Stephen T. Newman

doi:10.1016/j.cirp.2025.04.069

Sustainability of polycarbonate recycling via additive manufacturing

Nan Yu, Yifan Yuan, Zicheng Zhu, Ruslan Melentiev, Long Ye, James Tinkler, Lukas Raddatz, Stephen T. Newman

Department of Mechanical Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

Polycarbonate (PC) is emerging as one of the fastest-growing engineering plastics, but its potential for its application in a circular economy requires further investigation. This research explores the technical feasibility, carbon footprint, and economic impact of recycling injection moulding PC waste via fused deposition modelling (FDM) at a biotechnology manufacturer plant in the UK. The results show that recycling moulded PC scrap using FDM yields 3D printed parts with 88–98 % of virgin PC mechanical properties, produces nearly 70 % less carbon footprint, and saves up to 88 % of costs than utilizing virgin PC material.

Original language	English
Journal	CIRP Annals
Early online date	28 Apr 2025
DOIs	https://doi.org/10.1016/j.cirp.2025.04.069
Publication status	E-pub ahead of print - 28 Apr 2025

Keywords

Additive manufacturing
Fused deposition modelling
Recycling

ASJC Scopus subject areas

Mechanical Engineering
Industrial and Manufacturing Engineering

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.cirp.2025.04.069

Cite this

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title = "Sustainability of polycarbonate recycling via additive manufacturing",

abstract = "Polycarbonate (PC) is emerging as one of the fastest-growing engineering plastics, but its potential for its application in a circular economy requires further investigation. This research explores the technical feasibility, carbon footprint, and economic impact of recycling injection moulding PC waste via fused deposition modelling (FDM) at a biotechnology manufacturer plant in the UK. The results show that recycling moulded PC scrap using FDM yields 3D printed parts with 88–98 % of virgin PC mechanical properties, produces nearly 70 % less carbon footprint, and saves up to 88 % of costs than utilizing virgin PC material.",

keywords = "Additive manufacturing, Fused deposition modelling, Recycling",

author = "Nan Yu and Yifan Yuan and Zicheng Zhu and Ruslan Melentiev and Long Ye and James Tinkler and Lukas Raddatz and Newman, {Stephen T.}",

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AU - Yu, Nan

AU - Yuan, Yifan

AU - Zhu, Zicheng

AU - Melentiev, Ruslan

AU - Ye, Long

AU - Tinkler, James

AU - Raddatz, Lukas

AU - Newman, Stephen T.

PY - 2025/4/28

Y1 - 2025/4/28

N2 - Polycarbonate (PC) is emerging as one of the fastest-growing engineering plastics, but its potential for its application in a circular economy requires further investigation. This research explores the technical feasibility, carbon footprint, and economic impact of recycling injection moulding PC waste via fused deposition modelling (FDM) at a biotechnology manufacturer plant in the UK. The results show that recycling moulded PC scrap using FDM yields 3D printed parts with 88–98 % of virgin PC mechanical properties, produces nearly 70 % less carbon footprint, and saves up to 88 % of costs than utilizing virgin PC material.

AB - Polycarbonate (PC) is emerging as one of the fastest-growing engineering plastics, but its potential for its application in a circular economy requires further investigation. This research explores the technical feasibility, carbon footprint, and economic impact of recycling injection moulding PC waste via fused deposition modelling (FDM) at a biotechnology manufacturer plant in the UK. The results show that recycling moulded PC scrap using FDM yields 3D printed parts with 88–98 % of virgin PC mechanical properties, produces nearly 70 % less carbon footprint, and saves up to 88 % of costs than utilizing virgin PC material.

KW - Additive manufacturing

KW - Fused deposition modelling

KW - Recycling

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SN - 0007-8506

JO - CIRP Annals

JF - CIRP Annals

ER -

Sustainability of polycarbonate recycling via additive manufacturing

Abstract

Keywords

ASJC Scopus subject areas

UN SDGs

Access to Document

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