In Situ Functionalisation and Upcycling of Post‐Consumer Textile Blends into 3D Printable Nanocomposite Filaments

Abstract The linear lifecycle of the textile industry contributes to the enormous waste generation of post‐consumer garments. Recycling or repurposing of post‐consumer garments typically requires separation of the individual components. This study describes a novel and facile chemo‐thermo‐mechanical method for producing extrudable pellets, involving one‐pot, 2,2,6,6‐Tetramethylpiperidine‐1‐oxyl (TEMPO)‐mediated oxidation of post‐consumer polycotton textiles, followed by mild mechanical treatment, all without isolating the constituents of the polycotton blend. The oxidized blend with high cellulose and carboxylate content of 1221 ± 82 mmol COO⁻ per kg of cotton, is pelletised into a masterbatch and further in situ extruded into nanocomposite filaments for 3D printing. The carboxyl groups introduced on the polycotton‐based filters enable cotton fibrillation into nanoscaled fibers during mechanical treatment and extrusion resulting to a variety of functional and high surface‐finish quality models, including filters and fashion accessories. The electrostatic interactions with positively charged species, such as methylene blue (MB), facilitate their adsorption from water while exhibiting promising adsorption capacities. The adsorption of MB follows the Freundlich model and depends on the printed porosity of the filter. A “trash to treasure” concept for textile waste is further corroborated through the use of the developed 3D printing filament into commodity products.