The Influence of Selected Parameters of Recycled Polyvinyl Butyral on the Sustainable Filament Extrusion Process

In recent years, sustainability has permeated nearly every aspect of our lives, and the manufacturing sector is no exception. The terms “sustainable manufacturing” and “zero-waste manufacturing” are now part of our everyday vocabulary. This study, which explores the influence of key parameters on the filament extrusion process using recycled polyvinyl butyral (PVB), which is an amorphous polymer commonly obtained from the glass recycling industry, has significant practical implications. By determining the optimal conditions for the extrusion process, we can enhance the mechanical properties of the produced PVB filament yarns and their printability. As a result of identifying errors, optimizing the process, and eliminating the resulting shortcomings, a fiber made of PVB material with a diameter of 1.75 mm (±0.06 mm) was created that can be used in most FDM devices. The length of the created fiber was approx. 20 m, and in the presentation of the results, it will be used for printing samples, adhesion tests to the printing mat, shrinkage tests, and tensile tests of the fiber. After removing all the shortcomings, the ideal extrusion temperature was at 155 °C. This temperature was verified using microscopic cross-sections, and deformations or changes were observed in their cross-sections. The deviation of the material currently undergoing testing for the adhesion of PVB to various types of print beds, which was found suitable for use in FFF devices, was 1.75 −0.25/+0.25. This, in turn, can significantly expand the application of these materials in additive manufacturing, thereby making a substantial contribution to the advancement of sustainable manufacturing.