Global plastic waste streams motivate routes that convert polyethylene terephthalate into durable, repairable parts through additive manufacturing. The central question addressed is whether a continuous reactive-extrusion process can transform polyethylene terephthalate flakes into vitrimer filaments that deliver high strength, heat resistance, and repairability with practical energy and cost. Developed a twin-screw reactive-extrusion route that couples grafting and vacuum devolatilization with in-line drawing to 1.75 mm filament, and verified transesterification and imine exchange using infrared spectroscopy, solid-state carbon nuclear magnetic resonance, gel fraction, and Flory–Rehner analysis. Rheology and stress-relaxation defined a topology-freezing window of 120–145 °C and activation energies of 148–190 kJ mol−1, guiding print settings and post-print repair schedules. Printing at 252–255 °C nozzle, 85 °C bed, and 0.20 mm layers produced consistent deposition; mechanical testing reached tensile strength up to 63 MPa, interlayer shear 28–30 MPa, and heat-deflection temperature of 120–125 °C. Weld repair at 150–180 °C restored about 80 % tensile strength, and five melt reprocessings retained about 95 % heat-deflection temperature with modest viscosity drift. Microscopy showed wider inter-bead necks and about 1.6 % porosity with nano-silica, consistent with tougher interfaces. Process energy use totaled 1.70 kWh kg−1 and modeled cost was $1.69 kg−1 with major contributions from feed at $0.752 and electricity at $0.345. The study demonstrates a scalable pathway to high-strength, heat-resistant, and repairable vitrimer parts from waste polyethylene terephthalate with quantified performance, energy, and cost.
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