3D Printing Materials: An Option for Sustainability

Topic Information

Dear Colleagues,

The 3D printing process is the newest method for creating materials with specific shapes that cannot be obtained using conventional methods such as molding, injection, extrusion and others. The 3D printing process can be applied to polymers, metals and composites, among others, on which filaments, powders or resins are deposited layer by layer to obtain three-dimensional pieces. The choice of material depends on the printing technology and the final application, ranging from prototypes to industrial-use parts, and, recently, applications in buildings.

A key issue that has arisen in recent years is sustainability, due the need to provide environmentally friendly conditions in order to assist future generations, which can be achieved using natural, social and economic resources.

Sustainable materials are those that have reduced environmental damage in their production, use and disposal, including recycled or natural resources, and that produce a low carbon footprint, including renewable, recyclable or biobased materials.

This Topic is focused on sustainable materials that can be obtained from all kinds of 3D printing processes, aiming to produce environmentally friendly materials that contribute to the circular economy and solve environmental issues.

Dr. José Luis Rivera-Armenta
Dr. Cynthia G. Flores-Hernández
Topic Editors

Keywords

Participating Journals

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Applied Sciences applsci	2.9	6.1	2011	15 Days	CHF 2400	Submit
Buildings buildings	3.4	5.6	2011	14.7 Days	CHF 2600	Submit
Journal of Composites Science jcs	4.6	6.7	2017	13.9 Days	CHF 1800	Submit
Materials materials	3.7	7.0	2008	14.4 Days	CHF 2600	Submit
Polymers polymers	5.8	11.0	2009	13.4 Days	CHF 2700	Submit

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Published Papers (7 papers)

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All Materials Polymers J. Compos. Sci. Applied Sciences Buildings

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19 pages, 1451 KB  

Open AccessArticle

Enhancing 3D Printability of Black Soldier Fly Protein-Based Composite Gels by Incorporating Grape Seed Anthocyanin: Rheology, Water State, Protein Secondary Structure, and Microstructure

by Wenyue Deng, Jingjing Liao and Chaofan Guo

Materials 2026, 19(14), 3005; https://doi.org/10.3390/ma19143005 - 12 Jul 2026

Abstract

This study used black soldier fly protein (BSFP) as a base material and added 0%, 1%, 2%, 3%, 4%, and 5% of grape seed anthocyanidins (GSAs) to prepare composite gels. Through the combined use of low-field nuclear magnetic resonance, Fourier transform infrared spectroscopy, [...] Read more.

This study used black soldier fly protein (BSFP) as a base material and added 0%, 1%, 2%, 3%, 4%, and 5% of grape seed anthocyanidins (GSAs) to prepare composite gels. Through the combined use of low-field nuclear magnetic resonance, Fourier transform infrared spectroscopy, scanning electron microscopy, and rheometry, the relationships among GSA dosage (0–3%), gel structural properties (secondary protein conformation, water status, and microscopic morphology), and rheological printability were systematically evaluated. It was found that the better GSA content fell within 1–3%, and under this condition the extrusion-type 3D printing performance of the composite gels was significantly enhanced. At a 3% addition amount, the proportion of disordered conformations decreased (random coiling decreased from 15.93% to 15.46%), the ordered structure increased (β-sheet increased from 35.25% to 35.43%), and deformation resistance was enhanced. Low-field nuclear magnetic resonance showed an increase in the proportion of non-flowing water and an increase in physical constraints. Scanning electron microscopy showed a reduction in pore size and a thickening of pore walls, forming a denser 3D network. Rheologic analysis indicated that 3% GSA reached the maximum zero-shear viscosity (η₀) and that the storage modulus (G′) and loss modulus (G″) were higher in the experimental group than those in the control group. Printing fidelity increased from 45.73% in the control group to 60.08% in the 1% group, 62.14% in the 2% group, and 71.05% in the 3% group (p < 0.05). The 3–5% groups (fidelity: 71.05–75.66%) all achieved hollow cylindrical printing without collapse and had excellent self-supporting performance. However, excessive addition (4–5%) caused excess GSA to adsorb onto the protein skeleton surface, reducing the apparent viscosity and damaging the printing performance. Based on all the indicators, the composite gel with 3% GSA achieved the best balance between printability and structural integrity. Our research offers a new idea for using flavonoid compounds to improve the 3D printing performance of insect protein gels. The prepared composite gels can be used as food printing inks and applied to personalized nutrition customization, functional food development, and sustainable protein alternative product fields. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

14 pages, 2777 KB  

Open AccessArticle

Comparative Evaluation of PLA and PETG Drawer Slides and Conventional Metal Systems for Furniture

by Yarkın Pasa Kurt, E. Seda Erdinler and Sedanur Seker

Appl. Sci. 2026, 16(12), 6110; https://doi.org/10.3390/app16126110 - 17 Jun 2026

Viewed by 307

Abstract

The increasing demand for sustainable and lightweight furniture systems has driven interest in additively manufactured polymer components as alternatives to conventional metal hardware. However, their performance at the functional assembly level under standardized loading conditions remains insufficiently explored. This study evaluates the feasibility [...] Read more.

The increasing demand for sustainable and lightweight furniture systems has driven interest in additively manufactured polymer components as alternatives to conventional metal hardware. However, their performance at the functional assembly level under standardized loading conditions remains insufficiently explored. This study evaluates the feasibility of replacing metal drawer slides with fused deposition modeling (FDM)-based polymer alternatives fabricated from polylactic acid (PLA) and polyethylene terephthalate glycol (PETG). Unlike previous studies focused on material-level characterization, this work investigates fully functional drawer slide assemblies integrated into medium-density fiberboard (MDF) systems, enabling component-level assessment under realistic conditions. Specimens were designed in SolidWorks and fabricated under controlled printing parameters. Commercial metal slides were used as benchmarks. Mechanical performance was tested according to BS EN standards, and deformation was measured at multiple points. Statistical analysis included ANOVA, Tukey HSD, and t-tests at a 95% confidence level. Results showed significant differences among materials (p < 0.05). Metal slides exhibited the highest stiffness and minimal deformation. PLA showed stable performance with minor surface degradation, while PETG demonstrated lower dimensional stability and premature failure due to higher compliance. Overall, PLA-based FDM components offer a cost-effective alternative for non-heavy-duty applications, whereas PETG requires further optimization. The study bridges additive manufacturing and real-world furniture component performance under standardized testing. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

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18 pages, 10866 KB  

Open AccessArticle

Investigating Rheological Behavior of Chlorella vulgaris Starch: Implications for 3D Printable Bioplastic Material

by Kokeb Hurruma Jiru, Hirpa G. Lemu, Eyosias Tamerat and Mesay Tolcha

Polymers 2026, 18(12), 1452; https://doi.org/10.3390/polym18121452 - 10 Jun 2026

Viewed by 262

Abstract

The increasing demand for sustainable materials in additive manufacturing has driven the development of bioplastics derived from renewable biomass, including microalgae. In this study, the rheological behavior of a 20 wt.% aqueous gel prepared from native Chlorella vulgaris (C. vulgaris) starch, plasticized with [...] Read more.

The increasing demand for sustainable materials in additive manufacturing has driven the development of bioplastics derived from renewable biomass, including microalgae. In this study, the rheological behavior of a 20 wt.% aqueous gel prepared from native Chlorella vulgaris (C. vulgaris) starch, plasticized with 30 wt.% glycerol, was investigated to assess its suitability for extrusion-based 3D printing (direct-ink-writing, DIW). Steady shear analysis revealed a pronounced yield stress (${\tau }_0$ = 271.93 Pa) and strong shear-thinning behavior, described by the Herschel–Bulkley model (K = 59.47 Pa·sⁿ, n = 0.67), indicating structural stability at rest and efficient flow under shear. Oscillatory measurements confirmed a predominantly elastic response, with storage modulus (G′ $\approx$ 13,500 Pa) greatly exceeding loss modulus (G″) and a low loss factor (tan $\delta \approx$ 0.1), demonstrating gel integrity and shape retention. Temperature-dependent analysis indicated enhanced network strength without thermal softening, while thixotropic recovery tests showed rapid structural rebuilding after shear removal. Notably, a $~$50% increase in G′ during recovery highlights improved interlayer adhesion potential. These results show that C. vulgaris starch exhibits the key rheological characteristics required for DIW-type extrusion printing, including yield stress, shear-thinning behavior, viscoelastic stability, and rapid recovery, making it a promising candidate for this application. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

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19 pages, 2719 KB  

Open AccessArticle

Study on Strain Distribution and Crack Evolution Law of a Scaled 3D-Printed Utility Tunnel Model Under Vertical Load

by Peixi Guo, Enmu Ge, Hanwen Zhang, Ming Lin, Yao Zhang, Hang Jia, Xinyu Fan and Aijun Zhang

Buildings 2026, 16(11), 2154; https://doi.org/10.3390/buildings16112154 - 28 May 2026

Viewed by 251

Abstract

To investigate the failure characteristics of 3D-printed concrete utility tunnels under loading, a 1:25 scaled model was designed using similarity theory. Vertical loading tests were conducted under soil lateral confinement, and the load–displacement curves, discrete-point strain responses, and crack evolution process were obtained. [...] Read more.

To investigate the failure characteristics of 3D-printed concrete utility tunnels under loading, a 1:25 scaled model was designed using similarity theory. Vertical loading tests were conducted under soil lateral confinement, and the load–displacement curves, discrete-point strain responses, and crack evolution process were obtained. The test results show that the structure successfully undergoes an elastic stage, a crack development stage, and a plastic failure stage. The incorporated polypropylene fibers exert a bridging effect, enabling the component to retain a certain load-bearing capacity after cracking. Crack distribution was highly heterogeneous: cracks were densest on the top slab, widest on the side walls, and multi-directional on the inner wall. A clear correspondence exists between strain response and crack distribution, with tensile strain zones highly coinciding with crack opening zones. The failure mode generally agrees with the “top slab compression–side wall tensile cracking” characteristic of traditional closed-frame structures. However, the wall thickness deviations induced by the 3D printing process are amplified during internal force redistribution in the statically indeterminate structure, resulting in markedly asymmetric failure of the left and right side walls. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

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18 pages, 4516 KB  

Open AccessArticle

Surface Modification of FeSiB Soft Magnetic Amorphous Powders for High Processability in 3D Direct Writing

by Xinjie Yuan, Yongxing Jia and Jing Hu

J. Compos. Sci. 2026, 10(4), 217; https://doi.org/10.3390/jcs10040217 - 21 Apr 2026

Viewed by 838

Abstract

Soft magnetic composite materials have a low total loss and high magnetic conductivity and are highly desirable for high-frequency motors, semiconductors, and 5G communication technologies. However, these composites often contain a high-volume fraction of soft magnetic metallic powders and are difficult to process [...] Read more.

Soft magnetic composite materials have a low total loss and high magnetic conductivity and are highly desirable for high-frequency motors, semiconductors, and 5G communication technologies. However, these composites often contain a high-volume fraction of soft magnetic metallic powders and are difficult to process into complex shapes. Herein, iron-based amorphous powders were surface-modified with silane coupling agents (DTMS and KH570) and applied in 3D direct ink writing (DIW). The modified powders exhibit improved compatibility and dispersion in epoxy resin. The optimized 92.3 wt% FeSiB@3.35 wt% KH570/EP slurry shows favorable rheological properties and a dense interfacial microstructure. The printed composite achieves the best magnetic performance (M_s: 137.02 ± 1.2 emu/g, H_c: 6.63 ± 0.2 Oe) and stable permeability up to 1 GHz. The surface modification enhanced slurry fluidity, preventing nozzle blockage and increasing powder loading. Various shaped magnetic cores were successfully fabricated with excellent magnetic properties and printing quality. Our work paves a new way for realizing the high processibility of soft magnetic composites, which lays a foundation for a technique for the wide applications of these materials in various electronic devices. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

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17 pages, 3585 KB  

Open AccessArticle

Feasibility Study of Manufacturing Hydraulic Fittings Using Additive Manufacturing Technologies: Comparative Analysis of FDM and SLA Methods

by Jakub Backiel, Pawel Dzienis, Karol Golak, Przemysław Zamojski, Maciej Rećko, Rafał Grądzki, José Emiliano Martínez and Rogelio Valdés

Materials 2026, 19(4), 799; https://doi.org/10.3390/ma19040799 - 18 Feb 2026

Cited by 1 | Viewed by 663

Abstract

This paper investigates the feasibility of manufacturing hydraulic fittings using additive manufacturing (AM) technologies, specifically Fused Deposition Modeling (FDM) and Stereolithography (SLA). The study addresses the environmental challenge of material waste in conventional fitting production by exploring 3D printing as an alternative manufacturing [...] Read more.

This paper investigates the feasibility of manufacturing hydraulic fittings using additive manufacturing (AM) technologies, specifically Fused Deposition Modeling (FDM) and Stereolithography (SLA). The study addresses the environmental challenge of material waste in conventional fitting production by exploring 3D printing as an alternative manufacturing method. Hydraulic fittings were designed using CAD software: SolidWorks 2022 and fabricated using FDM with PETG (Polyethene Terephthalate Glycol) material and SLA with UV-sensitive photopolymer resin. In present studies, on-destructive leak testing was conducted in accordance with PN-EN 1254-4 and PN-EN 1254, at pressures ranging from 0.1 to 1.0 bar. Dimensional accuracy analysis revealed shrinkage of approximately 1% for SLA-printed parts and 2% for FDM-printed parts. Microscopic examination at 50× and 80× magnification showed superior thread quality in SLA samples compared to FDM, which exhibited visible layer separation and material porosity. Leak testing demonstrated that while the brass reference fitting maintained complete seal integrity, both 3D-printed variants failed to achieve leak tightness under operational pressures, with structural failure occurring at 1.0 bar during tightening. The study showed that FDM with PETG material and SLA with UV-sensitive photopolymer resin, despite achieving acceptable dimensional tolerances (±1–2%), do not meet hydraulic leak tightness requirements at pressures exceeding 0.5 bar in their raw state after printing. The results suggest that alternative material formulations (e.g., carbon fiber-reinforced PEEK for FDM or epoxy engineering resins for SLA) warrant further investigation. Potential avenues for improvement include advanced surface treatment, optimization of printing parameters, and modifications to thread geometry to reduce interthread gaps. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

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17 pages, 4391 KB  

Open AccessArticle

Fabrication of Highly Conductive Inkjet Printing Silver Nanoparticle Ink via a Synergistic Strategy Combining Centrifugal Classification and Dispersant Optimization

by Guo-Xiang Zhou, Yan Wang, Xing-Ping Zhou, Kuang Zhang, Zhi-Hua Yang, De-Chang Jia and Yu Zhou

Materials 2026, 19(3), 628; https://doi.org/10.3390/ma19030628 - 6 Feb 2026

Viewed by 849

Abstract

Inkjet printing technology shows significant potential for producing high-performance conductive circuits in printed electronics. However, conventional silver nanoparticle (Ag NP) inks often face challenges such as nozzle clogging, poor stability, and low conductivity after low-temperature sintering. While most existing studies focus solely on [...] Read more.

Inkjet printing technology shows significant potential for producing high-performance conductive circuits in printed electronics. However, conventional silver nanoparticle (Ag NP) inks often face challenges such as nozzle clogging, poor stability, and low conductivity after low-temperature sintering. While most existing studies focus solely on dispersant selection or individual process optimization, few have systematically explored the synergistic effects of particle size distribution, dispersion methods, and dispersant dosage. This study proposes a sequential optimization approach involving centrifugal classification to identify an optimal Ag NPs source and size distribution, followed by comparison and optimization of different dispersion methods. Furthermore, the effects of dispersant (a PEO-PPO-PEO triblock copolymer) concentration and application strategy (individual or combined use) on the rheological properties and conductivity of the ink were systematically investigated. The optimized Ag NP ink demonstrated excellent jetting stability with no nozzle clogging, exhibiting a surface tension of 19.60 mN/m and a viscosity of 6.83 mPa·s. After low-temperature sintering at 260 °C on glass or polyimide (PI) substrates, the printed patterns achieved a high electrical conductivity of 1.506 × 10⁷ S/m. Printing on polyethylene terephthalate (PET) at 150 °C confirmed compatibility with heat-sensitive flexible substrates. This work offers a comprehensive and practical strategy for developing highly reliable and conductive Ag NP inks, facilitating their application in next-generation printed electronics. Full article

(This article belongs to the Topic 3D Printing Materials: An Option for Sustainability)

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