Recyclability of TPU material - a sustainable perspective
As industries worldwide grapple with the pressing need for sustainable solutions, the role of advanced materials and innovative manufacturing techniques has never been more crucial. At Create it REAL, we are born green and part of the solution. Therefore, we are committed to minimizing our environmental impact by leveraging technologies that promote waste reduction, material recyclability, and a circular economy.
The transition to eco-conscious manufacturing practices starts with choosing repurposed materials and processes that naturally reduce waste. Thermoplastic Polyurethane (TPU) offers a unique opportunity to balance durability and sustainability. Paired with additive manufacturing techniques, TPU represents a step forward in reshaping how products are made—with the environment in mind.
Let’s explore how recyclable TPU and the efficiency of FDM 3D printing are paving the way for a more sustainable future.
Can TPU be recycled?
TPU is a versatile, durable, and flexible material commonly used in FDM 3D printing. The good news is that TPU can indeed be recycled. While TPU is not biodegradable, its thermoplastic nature allows it to be reshaped and reused multiple times through various recycling processes, reducing waste and contributing to a circular economy.
FDM 3D printing reduces waste
FDM 3D printing is a more sustainable manufacturing method than traditional production techniques like carving out foam blocks. In conventional methods, large amounts of material are cut away and discarded to achieve the desired shape, resulting in significant waste. Commonly, 30-60% of the foam block is wasted when producing a seat. For customized orthotic insoles produced in foam, the typical waste is around 30-50% but can be much higher depending on the complexity. In contrast, FDM printing is an additive process, meaning material is only used where needed. This reduces excess material and minimizes waste from the start, making it an environmentally friendly choice even before considering the recyclability of materials like TPU.
Recycling TPU: Process and applications
Recycling TPU involves shredding it into smaller pieces and reprocessing it. This can be either added to new filament for 3D printing or added to other materials to benefit from the TPU characteristics, such as flexibility, durability, or resistance to abrasion and chemicals. As a test, we have shredded and remelted TPU into recycled filament, which we can use to produce new prints. Aligned with our commitment to sustainable production, we are refining our print parameters to minimize material degradation, extending the lifecycle of the material. This optimization increases the potential for multiple reuses and strengthens our contribution to a more robust circular economy.
Practical considerations for recycling TPU
Recycling TPU can be more challenging for smaller operations or personal use. We recommend finding local recycling companies that can process TPU ware. For example, at the Create it REAL headquarters in Denmark, we have partnered with Stena Recycling, a leading European recycling company, to facilitate TPU recycling. Stena Recycling buys back TPU from us, demonstrating its commitment to sustainable practices. However, it’s important to note that most recycling companies typically require a minimum quantity of 500 to 1000 kg before accepting TPU for recycling.
Conclusion
With growing environmental concerns, finding ways to recycle TPU helps reduce plastic waste and makes 3D printing a more sustainable practice. We encourage individuals and businesses to explore recycling options, whether through internal efforts or partnerships with companies like Stena Recycling.
