3D Printer Thread Manufacturing From Microplastics Recovered From the Ocean

Marine microplastic (MP) pollution represents a pervasive environmental crisis, necessitating scalable and economic remediation strategies. This study demonstrates a “Zero Plastic” circular economy model by integrating the Active Marine Microplastic Remediation System (AMMRS) into the logistics of commercial shipping vessels. This passive filtration technology was utilized to recover MPs from the Mediterranean Sea, which were then characterized and repurposed into functional 3D printing filaments. Characterization via ATR-FTIR and DSC revealed a material profile dominated by Polyethylene (PE) and Polypropylene (PP), constituting 70 to 80% of the recovered mass. A multi-stage mechanical recycling workflow, comprising densifying, crushing, and extrusion, was developed to transform these degraded marine polymers into standardized threads. Despite the prevalence of PLA and PETG in the 3D printing market, our findings validate that recycled marine PE and PP offer a highly economic and technically viable alternative. The feasibility of this circular approach was confirmed by the successful production of various functional prototypes, including industrial pins and aesthetic accessories, using a standard FDM printer (Flashforge Adventurer 5M). This research provides a tangible blueprint for turning ocean waste into industrial feedstock, supporting both marine conservation and sustainable additive manufacturing.