Recycling of Selective Laser Sintering Waste Nylon Powders into Fused Filament Fabrication Parts Reinforced with Mg Particles

This paper presents recycling of selective laser sintering (SLS) waste nylon into printable filaments and parts reinforced with Mg particles. Waste nylon and waste–Mg powder mixture with 2%, 4%, and 8% Mg to nylon were extruded into the filaments. Moisture absorption, differential scanning calorimetry, and melt flow index experiments were conducted to determine the thermal characteristics, while tensile and flexural tests were conducted to evaluate mechanical properties and failure mechanisms. The results were compared with off-the-self (OTS) nylon. Waste powder was found to be extrudable and printable as FFF filament. Waste filament diameter closely matched standard filament size, while exhibiting reduced moisture absorption. High melting and crystallisation temperature for the waste nylon demonstrated a degradation of the plastic during the SLS process. Young’s modulus and ultimate tensile strength for the waste filament increased by 1.6-fold compared to that for OTS, while Mg-composite filament surpassed the waste and OTS. Waste and Mg composite dog bone results showed an increase in strength and stiffness, but the ductility deteriorated. Both flexural strength and modulus for the waste nylon increased by 13% and 26%, respectively, over OTS, and the addition of Mg enhanced flexural strength by up to 5-fold at 8% Mg over the waste. Printed surface topography demonstrated that the waste and Mg composite filaments can print the parts with desired geometric shapes and acceptable surface texture. The findings showed that recycling waste SLS powder into FFF prints would be a viable and useful alternative to disposal, given its abundance.