Progress in 3D printing of recycled PET

Abstract

Filaments from blends of post-industrial, low-quality recycled poly(ethylene terephthalate) (RPET) and ethylene-butyl-acrylate-glycidyl-methacrylate (EBA-GMA) were extruded with different EBA-GMA contents, then specimens were 3D-printed by fused filament fabrication technology. It has been demonstrated that, when 0–90° layer order is applied, at 15 wt% EBA-GMA content the unnotched impact strength increases by two and a half times and the notched impact strength by nine times compared to samples printed from elastomer-free RPET. DSC and DMA measurements proved that EBA-GMA reactively bonds to PET molecules, which is indicated by the increment of rigid amorphous phase and glass transition temperature and the reduction of crystallinity. The co-polymer molecules formed in-situ during compounding create a Toughening Enhancer Interphase (TEI), which also remains after 3D printing and effectively enhances impact strength. The strain at break and tensile strength of the filaments are substantially higher than that of 3D-printed specimens due to the increasing shrinkage and the resulting increased porosity of the printed specimens with higher EBA-GMA content. However, the Young-modulus values are quite similar. The flexural strength of the 3D-printed specimens reaches 40–60% of the values of injection moulded samples. The proposed method enables the production of parts with arbitrary geometry and balanced mechanical properties from RPET, which may substitute acrylonitrile butadiene styrene.