Closed-Loop Recycling of 3D-Printed Wood–PLA Composite Parts: Effects on Mechanical and Structural Properties via Fused Filament Fabrication

This study investigated the closed-loop recycling of 3D-printed wood fiber (WF)-filled polylactic acid (PLA) composites via fused filament fabrication (FFF). The WF-PLA composites (WPCs) were extruded into WPC filaments (WPC_fs) to produce FFF-printed WPC parts (WPC_ps). The printed WPC_ps were reprocessed three times via extrusion and 3D-printing processes. The tensile properties and impact strengths of the WPC_fs and WPC_ps were determined. To further investigate the impact of closed-loop recycling on the surface morphology, crystallinity, and molecular weight of WPC_fs, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and gel permeation chromatography (GPC), respectively, were used. After closed-loop recycling, the surface morphology of the WPC_fs became smoother, and a decrease in the pore sizes was observed; however, the tensile properties (tensile strength and elongation at break) deteriorated. With increasing numbers of recycling iterations, the molecular weight of the PLA matrix decreased, while an increase in crystallinity was observed due to the recrystallization of the low-molecular-weight PLA molecules after recycling. According to the SEM images of the recycled WPCps, their layer heights were inconsistent, and the layers were rough and discontinuous. Additionally, the color difference (Δ<i>E</i>*) of the recycled WPC_ps significantly increased. Compared with those of the WPC_ps after recycling them only once, the tensile strength, elongation at break, and impact strength of the WPC_ps noticeably decreased after recycling them twice. Considering the changes in various properties of the WPC_fs and WPC_ps, the FFF-printed WPC parts can be reprocessed only once through 3D printing.