Sustainable 3D Printing with Recycled PETG: Mechanical Characterization and Process Optimization in FDM Technology

As additive manufacturing becomes increasingly relevant for sustainable production, the mechanical reliability of parts made from recycled materials remains a subject of concern. In single-piece or low-volume manufacturing, the ability to predict part quality and structural behavior is crucial, especially when rework or failure incurs high costs. This study explores the feasibility of using recycled PETG filament in FDM (Fused Deposition Modeling) 3D printing, comparing its mechanical properties to those of virgin PETG. Standardized test specimens are designed and fabricated for tensile, bending, and impact testing. All samples are produced on a Creality Ender 3 printer and evaluated using universal testing machines under controlled conditions. The results reveal that recycled PETG demonstrates comparable elastic behavior to virgin material, though slightly lower maximum strength. Differences in performance under tensile and impact stress are most notable, with virgin PETG showing higher resistance to rupture. The findings highlight the potential of recycled PETG for non-critical load-bearing applications and emphasize the importance of optimized printing parameters to enhance material performance. This work contributes to broader efforts in sustainable additive manufacturing by demonstrating the viability of recycling in functional part production.