Valorization of Waste Powder from Selective Laser Sintering: An Opportunity for the Circular Economy

The widespread adoption of additive manufacturing, particularly selective laser sintering (SLS), has raised concerns about the disposal of unused thermoplastic powder residues, such as polyamide 12 (PA12). The high cost of PA12 and its degradation during the SLS process highlight the need for sustainable reuse strategies. This study evaluates the feasibility of reprocessing non-sintered PA12 powder without the addition of virgin material through fused deposition modeling (FDM) and injection molding (IM). Thermal analysis showed that the material retains processing temperatures comparable to virgin PA12. However, a significant reduction in melt flow index (≈61%) was observed, reflecting reduced processability and suggesting molecular-level changes affecting chain mobility. Injection molding demonstrated consistent mechanical behavior and good ductility, confirming its suitability for processing recycled PA12. In contrast, FDM processing resulted in higher variability and reduced ductility, mainly due to limitations in interlayer bonding associated with the increased viscosity of the material. Overall, the results highlight injection molding as a robust route for the valorization of non-sintered PA12, while FDM remains a feasible but less reliable alternative requiring further optimization.