A Comprehensive Review on the Utilization of Recycled Polylactic Acid in Fused Deposition Modelling 3D Printing for Sustainable Manufacturing

ABSTRACT

Fused deposition modelling (FDM) has emerged as one of the most widely adopted additive manufacturing technologies because of its ability to fabricate complex geometries and produce rapid prototypes efficiently. However, the increasing reliance on virgin polymer materials has raised concerns regarding excessive raw material consumption and the accumulation of plastic waste. In response to these environmental challenges, recycled polylactic acid (PLA) has gained significant attention as a sustainable material for FDM 3D printing. This review focuses exclusively on recycled PLA and provides a comprehensive overview of recent developments in recycled PLA filaments. It examines the effects of recycling on the mechanical, thermal and rheological properties of PLA, which directly influence filament printability and the performance of printed components. In addition, the review discusses common printing challenges associated with recycled PLA, including poor surface finish, warpage and weak interlayer adhesion. Key issues limiting the widespread adoption of recycled PLA, such as material degradation after multiple recycling cycles, contamination during recycling and the optimization of printing parameters, are also critically evaluated. Furthermore, potential strategies for improving the performance of recycled PLA, based on findings from previous studies, are presented. Finally, the review identifies existing research gaps and highlights future opportunities for advancing recycled PLA as a sustainable material for FDM, thereby contributing to more environmentally responsible additive manufacturing practices.