| Abstract Scope |
A novel approach to upcycling recycled polypropylene (r-PP) by incorporating zeolites as functional fillers for 3D printing and injection molding applications. Zeolite concentrations ranging from 0 to 30 wt% were investigated for their impact on filament quality, thermal behavior, and mechanical properties. Optimized extrusion enabled smooth filament fabrication, while microscopy revealed improved dispersion at lower filler loadings. Peak mechanical performance was observed at 10 wt% zeolite, with 3D-printed samples achieving 29.25 MPa tensile and 39.21 MPa flexural strength, and injection-molded samples reaching 34.29 MPa and 43.32 MPa, respectively. Higher loadings led to agglomeration and voids, reducing performance. Polypropylene tape improved bed adhesion and print quality. The addition of zeolites enhanced surface finish, offered potential VOC suppression, and improved thermal stability. This work demonstrates a scalable route for converting plastic waste into high-value composites, advancing circular economy goals and expanding the utility of recycled PP in automotive, construction, and packaging sectors. |