Recycling contaminated wastepaper using composite-based additive manufacturing

Abstract

Composite Based Additive Manufacturing (CBAM) is an additive manufacturing process for fabricating lightweight, high-strength fiber-reinforced polymer (FRP) composites. The CBAM process uses polymer powder and sheets of non-woven fiber as feedstocks. These sheets and polymer particles are selectively stacked layer by layer and pressed to make a complex part. In this paper, we present the use of the CBAM process in recycling wastepaper, particularly those with contaminants, into value-added FRP composites. Thin sheets of paper fibers are recycled from wastepaper pulps. The properties of the recycled sheets of paper fibers (e.g., thickness, porosity, strength) are studied through controlling the concentrations of pulp/water and strengthening agents (e.g., linen fibers). The effects of waterproofing spray of the fiber sheets are investigated to enhance the powder capture. The proposed method offers a cost-effective route to recycle wastepaper with contaminants into value-added composite products, which would otherwise go to the landfill. Making products from recycled wastepaper has a positive effect on the environment and can help reduce the cost of the CBAM technology, for which the feedstock materials account for over 60 % of the total cost.