Closing the loop in healthcare: chemically recycled ABS for 3D printing of medical device

Introduction The integration of three-dimensional (3D) printing into Point‐of‐Care (POC) healthcare has enabled the rapid production of patient-specific medical devices, including anatomical models and surgical guides. However, the increasing use of additive manufacturing in clinical settings raises environmental concerns related to the consumption of virgin polymers and the generation of plastic waste. Circular economy approaches based on recycled materials may represent a more sustainable alternative, provided that the safety, biocompatibility, and manufacturing requirements of medical applications are preserved. This study investigated the feasibility of using chemically recycled acrylonitrile butadiene styrene (ABS) for the fabrication of non‐implantable medical devices by Fused Deposition Modeling (FDM). Methods The chemically recycled ABS used in this study was produced using Versalis’ proprietary technology. The recycled ABS was first chemically characterized to assess its suitability for biomedical use. It was then processed into 1.75 mm filaments and used to manufacture standardized specimens and proof‐of‐concept patient‐specific devices in an ISO 13485‐certified laboratory. Dimensional accuracy and process repeatability were evaluated, while biological performance was assessed through direct cytotoxicity testing according to ISO 10993‐5 using L929 fibroblasts. The results were compared with those obtained using a certified medical‐grade ABS reference material. Results Chemically recycled ABS showed a chemical profile compatible with current regulatory requirements and was successfully processed into high‐quality FDM filaments and printed components. The printed specimens demonstrated high dimensional accuracy and reproducibility, supporting the suitability of the material for geometrically demanding medical applications. Cytotoxicity testing confirmed that the recycled ABS was non-cytotoxic in all tested forms, with 3D-printed samples showing a cytocompatibility profile comparable to that of the certified medical-grade ABS reference material. In addition, patient‐specific anatomical models and surgical guides were successfully fabricated, demonstrating the applicability of the material within clinically relevant POC workflows. Discussion Overall, these findings indicate that chemically recycled ABS represents a promising and sustainable alternative to virgin polymers for the FDM manufacturing of non‐implantable medical devices. This study provides evidence that circular materials can be integrated into hospital‐based additive manufacturing without compromising the safety, biocompatibility, or manufacturing performance evaluated in this study, thereby supporting the transition toward more sustainable Point‐of‐Care production systems.