Core–shell configuration of virgin and recycled ABS via 3D printing

Abstract

3D printing is a versatile technique to produce polymer mechanical parts. Acrylonitrile–butadiene–styrene (ABS) plastic has been widely used in fused deposition modeling (FDM), due to its good mechanical and thermoplastic properties. This study aimed to assess the feasibility of incorporating recycled ABS without compromising the mechanical integrity of pieces, by using a core–shell configuration. Test specimens with a virgin ABS shell and a recycled ABS infill are made with a commercial dual-extruder 3D printer. The impact of thermal extrusion cycles on the mechanical properties of ABS used in FDM 3D printing was evaluated. The results indicate a gradual decline in mechanical performance with increasing number of recycling cycles. However, specimens with a hybrid composition (virgin ABS shell and recycled ABS infill) maintained acceptable mechanical properties, demonstrating the potential of this approach for sustainable 3D printing practices. The findings highlight the viability of using recycled ABS in additive manufacturing, offering a sustainable approach without compromising structural integrity.