LOW-COST SUSTAINABLE MANUFACTURING SYSTEMS USING RECYCLED MATERIALS AND DIGITAL FABRICATION

Abstract

Plastic waste, particularly polyethylene terephthalate (PET), poses a significant environmental challenge due to its high volume and low recycling rates. This study aims to evaluate the feasibility of producing low-cost, sustainable 3D printing filament from recycled PET using digital fabrication techniques. The objective is to assess both the mechanical performance and economic viability of recycled PET filament for application in small-scale manufacturing systems. A quantitative experimental methodology was adopted, utilizing a Design of Experiments (DOE) approach to analyze the effects of selected variables, including material type and processing parameters, on filament yield and compressive strength. Recycled PET bottles were processed into filament, and test specimens were fabricated using fused deposition modeling (FDM). Mechanical testing and cost analysis were conducted, with statistical evaluation performed using ANOVA. The findings reveal that recycled PET can produce filament with acceptable mechanical properties, with variations in strength influenced by material characteristics and processing conditions. Larger PET bottles yielded more filament, while optimized printing parameters improved strength performance. The total production cost was significantly lower than commercial filament, confirming economic feasibility, although labor remained the dominant cost factor. In conclusion, recycled PET filament production is a viable, cost-effective, and sustainable alternative to conventional materials. It supports waste reduction and promotes circular manufacturing practices. It is recommended that future work focus on process optimization, automation, and scalability to further enhance efficiency and broaden industrial application.