The Quest for the Holy Grail Of 3D Printing: A Critical Review of Recycling in Polymer Powder Bed Fusion Additive Manufacturing

The benefits of additive manufacturing (AM) are widely recognised, boosting the AM method’s use in industry, while it is predicted AM will dominate the global manufacturing industry. Alas, 3D printing’s growth is hindered by its sustainability. AM methods generate vast amounts of residuals considered as waste, which are disposed of. Additionally, the energy consumed, the materials used, and numerous other factors render AM unsustainable. This paper aims to bring forward all documented solutions in the literature. The spotlight is on potential solutions for the Powder Bed Fusion (PBF) AM, focusing on Selective Laser Sintering (SLS), as these are candidates for mass manufacturing by industry. Solutions are evaluated critically, to identify research gaps regarding the recyclability of residual material. Only then can AM dominate the manufacturing industry, which is extremely important since this is a milestone for our transition into sustainable manufacturing. This transition itself is a complex bottleneck on our quest for becoming a sustainable civilisation. Unlike previous reviews that primarily concentrate on specific AM recycling materials, this paper explores the state of the art in AM recycling processes, incorporating the latest market data and projections. By offering a holistic and forward-looking perspective on the evolution and potential of AM, this review serves as a valuable resource for researchers and industry professionals alike.