Fused Filament Fabrication of Recycled <scp>HDPE</scp> and Cactus Composite as a Biobased Material

ABSTRACT Plastic pollution has emerged as a significant global issue, highlighting the need for sustainable alternatives and effective recycling methods. Concurrently, the cactus plant offers a promising source of bio‐based materials, particularly due to its resilience in harsh environments. This study focused on the performance characterization of cactus powder mixed with recycled high‐density polyethylene (rHDPE) pellets for filament production suitable for 3D printing using the Fused Filament Fabrication method. The physical properties of both cactus and rHDPE were investigated, and composite filaments were prepared from 5%, 10%, and 15% cactus powder alongside rHDPE. Performance evaluation of the composite filaments was conducted using a Universal Testing Machine. Additionally, the chemical composition of cactus powder was analyzed, and the particle size distribution was determined. The combination of HDPE pellets and cactus powder yielded a viable filament, though increasing proportions of cactus reduced the extrusion properties. The tensile strength of pure rHDPE filament was measured at 16.27 MPa, while the tensile strengths for the 5% and 10% cactus composites were 14.97 and 10.74 MPa, respectively. For the printed specimens, the tensile strength was recorded at 13.04 MPa for rHDPE and 8.28 MPa for the 5% cactus composite. The flexural strength results showed 21.77 MPa for rHDPE and 15.64 MPa for the 5% cactus composite. These findings suggest that cactus powder can serve as a valuable additive in developing sustainable 3D printing materials.