107: Sustainable 3D Printing with HDPE PLA Blends

3-D printing has changed manufacturing by allowing fast prototyping, customization and creation of complex shapes. Among popular materials, polylactic acid (PLA) is valued because it breaks down naturally and is easy to use, while recycled high-density polyethylene (HDPE) offers a sustainable option by reusing plastic waste. Mixing these materials into a composite filament improves the environmental impact of 3-D printing while lowering costs. This study looked at how PLA/recycled HDPE composite filaments perform, focusing on how well they work together, print and where they might be used.

To test these composite filaments, we ran rheological and dynamic mechanical analyses (DMA) on different mixtures of recycled HDPE and PLA. We used rheology to study how the materials flow at high temperatures. DMA helped us understand the composite’s strength at room temperature, showing us how it bends and where it might be useful.

We found that adding more HDPE to PLA made the material less stretchy and weaker. However, some mixtures stayed strong and flexible enough for 3-D printing. Our data showed that a 30/70 HDPE-to-PLA mix worked best, performing similar to materials you can buy commercially. Using recycled HDPE not only cuts costs but also creates a more sustainable option for 3-D printing.

This study showed that recycled HDPE/PLA composite filaments offer a workable and sustainable alternative to traditional materials, with real potential for helping the environment and education. Future research will focus on improving production methods and finding more uses for this innovative material.