Valorization of recycled fine powder glass (RFPG) in additive manufacturing: Optimization of the RFPG content in polyethylene terephthalate glycol (PETG) and multi-response analysis

• Reinforcement of MEX 3D printed parts with the sustainable fine powder recycled glass. • The high durability Polyethylene terephthalate glycol was the matrix. • Sustainable composites achieved high-performance mechanical properties. • 8 wt% composite improved 16.3 % the tensile strength. A cyclic economy and sustainability-driven production are key aspects of the industry. Recycled feedstocks are steadily replacing virgin materials to produce parts and as sustainable additives to develop eco-friendly composites. The reinforcing potential of recycled fine powder glass (FPG) on terephthalate glycol (PETG) is investigated. The performances of six different compounds (with FPG loadings of 2.0, 4.0, 6.0, 8.0, 10.0, and 12.0 wt%) in filament and three-dimensional (3D) specimens form (manufactured with the material extrusion – MEX method) were compared with PETG pure. This research included thermal and rheological analyses, mechanical tests, and morphological and structural investigations. According to these findings, the PETG/RFPG 8.0 wt% composite presented remarkable results in the tensile and flexural (16.3 % and 16.9 % strength increase, respectively) tests, while PETG/RFPG 10.0 wt% had the greatest performance concerning microhardness. Both the dimensional deviation and porosity results show excellent performance in the case of PETG/RFPG 6.0 wt%, by being 67.3 % and 87.1 % improved vs. the PETG pure. These results indicate that RFPG is a promising reinforcement additive for MEX 3D printing that can replace the commonly used inorganic fillers and promote the sustainability of 3D printing.