Recycling Post-Consumer Polypropylene Cutlery into 3D Printing Filaments for Fused Filament Fabrication

Ong, Shu Yong (2025) Recycling Post-Consumer Polypropylene Cutlery into 3D Printing Filaments for Fused Filament Fabrication. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This study focuses on the development and evaluation of 3D printer filament made from post-consumer polypropylene (PCPP) cutlery, aiming to reduce plastic waste through sustainable material reuse. A blend of injection-grade and extrusion-grade recycled PCPP was used to fabricate filament through extrusion. The filament was then characterized based on diameter consistency, ovality, and melt flow rate (MFR), followed by mechanical testing of 3D printed specimens. The results showed that blending extrusion-grade PCPP improved filament uniformity and reduced MFR, enhancing its suitability for fused filament fabrication (FFF). Tensile testing revealed that the mechanical properties were influenced by both filament composition and printing layer height, with the 0.4 mm and 0.6 mm layers performing better than 0.8 mm due to improved interlayer bonding. Comparative analysis with commercial PLA filament at 0.6 mm layer height showed that while PLA outperformed PCPP in tensile strength and stiffness, the recycled PCPP filament still demonstrated acceptable performance for non-structural 3D printed applications. This project highlights the potential of using recycled polypropylene in additive manufacturing, promoting material circularity and environmental sustainability.