Utilizing bio-energy and waste reduction techniques in FDM: Toward sustainable production practices

Additive manufacturing, particularly through fused deposition modeling (FDM), has significantly advanced rapid prototyping and customized production. However, traditional FDM practices raise environmental concerns due to energy use and waste generation. This research explores integrating bio-energy sources and advanced waste reduction techniques within FDM to enhance sustainable production practices. By implementing renewable energy sources and optimizing material usage, this approach aims to lower the carbon footprint associated with FDM. Our study reviews state-of-the-art methods such as biodegradable polymers, energy-efficient hardware, and waste-reducing design algorithms. Experimental results demonstrate that the use of recycled materials can maintain mechanical performance while enhancing sustainability. For instance, recycled PLA achieved a tensile strength of 52.4 MPa and an elongation at break of 6.1%, while recycled PHA showed a tensile strength of 59.4 MPa and an elongation at break of 5.5%. Both materials achieved high material recovery rates, with recycled PLA at 92.7% and recycled PHA at 90.2%, indicating effective closed-loop recovery. These findings indicate substantial reductions in material waste and energy consumption, promoting sustainable practices in both industrial and consumer-level FDM applications. This study contributes to the field of sustainable additive manufacturing by aligning with circular economy principles and addressing the global need for reduced environmental impact.