3D printing based on poplar waste: process optimization for enhanced mechanical properties

In response to the urgent demand for sustainable materials and manufacturing, this study explores a high-value pathway for converting forestry waste into functional products. This study systematically optimized the binder jetting 3D printing process for wood–plastic composite materials using poplar powder, a renewable and abundantly available forestry waste, as the raw material. Compared with traditional methods, this additive manufacturing approach minimizes material waste and energy consumption, significantly enhancing both material and energy utilization efficiency, thereby providing technical support for green manufacturing. Using the response surface methodology, the optimal combination of process parameters was determined as follows: adhesive saturation of 62.4%, layer thickness of 62.7 μm, printing speed of 58.6 mm/s, and curing time of 49.9 min. Under these conditions, the cured specimen achieved a density of 0.64 g/cm³, a flexural strength of 0.80 MPa, and a tensile strength of 0.69 MPa, demonstrating excellent mechanical performance. The established robust predictive model further validates the feasibility of wood–plastic composites that offer both superior performance and environmental benefits. This study presents a breakthrough solution for the high-value utilization of wood waste, strongly promoting the advancement of sustainable material science and the circular economy.