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From Waste to Resource: Transforming FDM
Printing with Recycled Materials via OpenAM
Introduction
As the additive manufacturing (AM) industry
continues to grow, so does its environmental footprint.
Integrating recycled materials into 3D printing
processes presents a critical opportunity to mitigate
this impact, particularly in reducing carbon emissions
and manufacturing waste. Utilizing a product like
OpenAM™ to unlock third-party materials for selectStratasys fused deposition modeling (FDM®) printers,
represents a significant leap towards sustainability inadditive manufacturing.

OpenAM Technology: 							An Overview
Stratasys FDM OpenAM is a software platform that enables customers to retune or create their own material recipeson the Fortus 450mc™ and F900® platforms. On these machines, OpenAM software allows users to innovate withnew materials and explore new use cases by providing the ability to adjust and create custom print parameters.

Becoming More Sustainable in AM
FDM has enjoyed 30 years of widespread adoption yet remains adaptable to current needs. For example, when firstlaunched, only virgin thermoplastics could be utilized. Now, to meet increasing demand, it is also possible to print
with recycled materials.
Using virgin thermoplastics in additive manufacturing is associated with high carbon emissions, largely due to theenergy-intensive processes involved in extracting raw materials and producing the final product. In contrast, recycling
thermoplastics for use in 3D printing significantly lowers the carbon footprint. Research has shown that recycledplastics can reduce carbon dioxide emissions for PETG by 35% compared to their virgin counterparts (1*). Recycling
ABS can lower CO2 emissions by 28% (2*)(3*).
OpenAM’s capability to process recycled materials not only extends the material’s life cycle but also contributes to a
substantial decrease in carbon emissions. By embracing recycled thermoplastics, the AM industry can significantly
lower its environmental impact and contribute to global carbon reduction efforts.

Reduce and Reuse Wherever Possible
OpenAM allows the use of any third party filament, enabling the utilization of recycled materials. This capability
reduces the demand for virgin plastics and impacts waste management practices within the industry. By recycling
end-of-life parts and waste materials into new 3D printing filament, OpenAM-equipped printers allow customers todivert waste from landfills. This approach aligns with sustainable waste management practices, emphasizing
material recovery and recycling over disposal.

Challenges and Limitations
The utilization of recycled thermoplastic materials in FDM 3D printing faces several
significant challenges:

Changes in Material Properties
Not all thermoplastic materials are as viable for the FDM process as others. For example, amorphous polymers tend
to exhibit more controllable printing behavior. Furthermore, observations of thermoplastic materials subjected torecycling processes show alterations in their material properties. These modifications can influence the properties
positively or negatively in the initial cycles. Nevertheless, it has been documented that, without intervention, ABS
demonstrates minimal degradation of material characteristics after five cycles (4*).
Research indicates that the thermal and chemical properties of the commonly used 3D printing materials PLA andABS undergo negligible alteration through recycling processes (4*). To address the decline in mechanical properties
observed after numerous recycling iterations, the incorporation of additives is a viable strategy. The introduction ofsuch additives can restore the initial material properties in an ABS/PLA blend, even after 20 recycling cycles (5*).

Navigating Economic, Logistical, and Quality Challenges in
Adopting Recycled Materials for AM
Integrating recycled materials into the AM process poses economic, logistical, and quality assurance challenges.
Collecting, sorting, and processing waste materials into a usable form for 3D printing can be complex. Moreover,maintaining the quality and consistency of these recycled materials is also a significant hurdle . Variabilities in wastematerial properties, compounded by contaminants, may lead to inconsistencies in filament specifications such as
diameter and roundness. This directly impacts the quality of the 3D printed products, highlighting the intertwined
nature of logistical and quality-related challenges of recycled materials in additive manufacturing.
Stratasys investigations have found that industrial production waste generates some of the best sources for recycled
filaments. Scraps or offcuts can be gathered from a single source and converted into new material, minimizing therisk of cross-contamination or complicated supply chains. For example, injection molding sprues and molding flash
are suitable raw materials for new filament production.

Case Studies and 								Real-World Applications
Jigs and fixtures are a necessary part of any manufacturing process. Usually made from metal, they’re often costly
and bulky, and many don’t require highly precise dimensions. They just need to secure a part for machining ormeasurement. These tools are highly suitable for replacement with lower-carbon polymers or even recycled
polymers.

CMM Measuring Fixture
CMM fixtures are another common device found on many shop floors. Often, they are only used a small number oftimes to measure parts but may have complex geometries. Fixtures like these are ideal candidates for printing from
100% recycled ABS since this material can easily meet the application requirements.

Vacuum Adapter
Stratasys engineers used a 3D printed vacuum adapter to push the limits of printing with 100% recycled ABS. They
chose to test its air-tightness and surface finish using a design that incorporated thin walls and overhangs. The
recycled ABS paired well with SR-30™ soluble support material and produced a usable and smooth surface on thefinal duct.

Conclusion
Recycled thermoplastics in AM, enabled by products like OpenAM, represent a pivotal movement toward moresustainable FDM technology. OpenAM’s enablement of third-party materials not only promotes the reduction ofcarbon emissions and waste but also encourages economic efficiency, material innovation, and the advancement ofa circular economy. As the AM industry continues to evolve, the importance of recycling and sustainable
manufacturing practices will undoubtedly grow.
In-house recycling can pose challenges but practical solutions are available such as third-party recycling services oropting to purchase pre-processed recycled materials from larger aggregators. This approach facilitates the seamlessintegration of sustainability efforts within operations.
Finally, OpenAM allows users to alter print parameters to their exacting requirements should the need arise, aparadigm shift in the AM material market. Never before has such a major industry player in the material extrusion
market opened up their platforms to customers’ individual needs. Which materials could you recycle with OpenAM?

References(1*) Armor Group. February 22, 2023. Kimya PETG Lifecycle analysis 35% CO2 savings compared to virgin material. Retrieved April, 2024, fromhttps://www.armor-group.com/en/actualites/provide-more-sustainable-alternatives(2*) Mishra, V., Negi, S., Kar, S., Ror, Ch K. (2023) Development of sustainable 3D printing filaments using recycled/virgin ABS blends: Processingand characterization. Retrieved from https://www.researchgate.net/publication/370022475_Development_of_sustainable_3D_printing_filaments_using_recycledvirgin_ABS_blends_Processing_and_characterization(3*) de Oliveira, R., Silva, M., Agrawal, P., Brito, G. (2023) Recycling of Acrylonitrile Butadiene Styrene from Electronic Waste for the Production ofEco-Friendly Filaments for 3D Printing. Retrieved from https://www.researchgate.net/publication/369339629_Recycling_of_Acrylonitrile_
Butadiene_Styrene_from_Electronic_Waste_for_the_Production_of_Eco-Friendly_Filaments_for_3D_Printing(4*) Hassan, M., Mohanty, A., Misra, M. (2023) 3D printing in upcycling plastic and biomass waste to sustainable polymer blends and composites:
A review. Retrieved from https://www.sciencedirect.com/science/article/pii/S0264127523009747(5*) Chiu, H.T., Huang, J.K., Kuo, M.T., Huang, J.H. (2018) Characterisation of PC/ABS blend during 20 reprocessing cycles and subsequentfunctionality recovery by virgin additives. Retrieved from https://doi.org/10.1007/s10965-018-1522-6

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