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Chemical Recycling: Transforming Plastic Waste

Introduction

In the ever-evolving landscape of 3D printing, businesses and innovators are constantly seeking ways to enhance efficiency, reduce waste, and advance sustainability. One significant hurdle in this quest has been recycling thermoset polymers, commonly used in technologies like SLA (Stereolithography), DLP (Digital Light Processing), and Polyjet. Unlike their thermoplastic counterparts, thermosets pose unique challenges in recycling due to their irreversible chemical cross-linking properties. However, the emergence of chemical recycling offers a promising solution to this longstanding issue, heralding a new era of sustainability in 3D printing.

As a 3D printing service, we know that the variety of materials and technologies available on the market can be confusing for the consumer. That is why we decided to make this comprehensive guide.

Understanding the Difference: Thermoplastic vs. Thermoset

Before delving into chemical recycling, it’s crucial to grasp the fundamental disparity between thermoplastic and thermoset polymers. Thermoplastics, characterized by their ability to soften when heated and harden when cooled, are recyclable through mechanical processes. This means they can be melted, reshaped, and reused multiple times without undergoing significant mechanical changes.

On the other hand, thermoset polymers undergo irreversible chemical reactions during their curing process, forming a network of cross-linked molecular structures. Once set, thermosets cannot be melted and reshaped like thermoplastics, rendering them non-recyclable through traditional mechanical methods. Because the acrylic or epoxy chemistry of resin materials like these cannot be recycled, any prints made with these resins are inevitably destined for landfills. 

The Promise of Chemical Recycling:

Chemical recycling holds the key to unlocking thermoset polymers’ untapped potential. Unlike mechanical recycling, which relies on grinding and melting processes, chemical recycling involves breaking down polymers into their molecular components, enabling them to be reconstituted into new materials. This revolutionary approach offers a sustainable solution for managing thermoset waste, transforming it into valuable feedstock for future 3D printing applications. See the illustration below:  

closed-loop chemical recycling graph

Why Does It Matter?

The significance of chemical recycling becomes apparent when considering the prevalent use of thermoset polymers in various 3D printing technologies. SLA, DLP, and Polyjet technologies exclusively utilize thermosets or resins, which account for a significant portion of the industry’s output. Due to the lack of viable recycling options, this output often becomes waste.

In 3D printing, the inability to recycle thermoset polymers poses significant sustainability and resource management challenges. As these technologies proliferate and diversify, addressing the end-of-life issues associated with thermoset waste becomes imperative. Chemical recycling offers a promising avenue for mitigating these concerns, providing a sustainable means of repurposing thermoset materials and reducing environmental impact. 

3d printing technologies used in 2024 chart

Connecting Chemical Recycling with 3D Printing:

Enabling the recycling of thermoset polymers, like EPD 1086 or Polyjet Veroclear, offers a viable solution for closing the loop on material utilization, reducing reliance on virgin feedstock, and minimizing waste generation.

Moreover, chemical recycling aligns with the broader goals of circular economy principles, wherein resources are kept in circulation for as long as possible through recycling and regeneration. For 3D printing engineers, this means greater flexibility in material sourcing, reduced environmental footprint, and enhanced cost-effectiveness in the long run. 

Conclusion

Chemical recycling is poised to revolutionize the 3D printing industry by enabling the recycling of thermoset polymers, which are widely used but traditionally non-recyclable. Scaling up this technology is crucial for its success. According to Plastics Europe, significant investments are needed to increase the capacity of chemical recycling facilities. The projected investment is set to rise from EUR 2.6 billion in 2025 to EUR 8 billion in 2030, aiming to produce 2.8 million tons of recycled plastics annually by 2030​ (Plastics Europe)​.

Such investments are essential for advancing the technology, enhancing efficiency, and meeting ambitious EU recycling targets. This will reduce the environmental impact of thermoset waste, fostering a circular economy within the 3D printing industry and beyond. 

Sculpteo’s commitment to sustainability is deeply tied to the principles of additive manufacturing. By optimizing the use of raw materials and minimizing production waste, Sculpteo defends the fundamental values ​​of sustainable development. The Re-cycleo program for recycling thermoplastic parts from the first unit demonstrates these values, reflecting our dedication to reducing environmental impact and promoting responsible manufacturing practices.

Interested in 3D printing and sustainability? Explore our e-book for more insights.

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