Recycled PP for 3D Printing: Material and Processing Optimization through Design of Experiment

In this work, blends that were based on first use PP added with talc (PPt) and recycled polypropylene (r-PP) were designed and formulated, aiming at producing filaments that are suitable for 3D printing fused filament fabrication (FFF) processes. A preliminary characterization of PPt/r-PP blends at different weight ratios allowed selecting two systems showing adequate rheological behavior for FFF. The selected blends were melt compounded in a twin-screw extruder, optimizing the processing conditions through a design of experiments approach, involving the use of Taguchi’s method. The materials that were prepared with the optimized processing conditions, hence showing the best performance in terms of rheological behavior and thermal characteristics, were then selected for the production of the filament and for the subsequent FFF processing. Finally, the morphology of the filament and the mechanical properties of 3D-printed samples were assessed, demonstrating the achievement of satisfactory results in terms of performances. In general, the obtained results clearly demonstrated that a proper optimization of both material and processing conditions offers the possibility of using recycled PP-based formulations for additive manufacturing processes, hence allowing a remarkable valorization of a low added-value material through its utilization for an innovative and sustainable manufacturing approach.