Andaltec develops material for SLS 3D printing from recycled polypropylene

The Andaltec Technology Center has begun research as part of the RECYPPOWDER project, which aims to develop a new family of innovative, economical and sustainable materials made from recycled polypropylene.

This innovation will be used to manufacture parts using Selective Laser Sintering (SLS), an advanced technology in the field of additive manufacturing. This project is part of the Spanish national public-private partnership for the promotion of scientific and technological research and is led by Innomaq 21, with the University of Barcelona and Andaltec as partners.

Polypropylene is known for its robustness, lightness and high resistance to tearing and fatigue, making it an ideal material for functional prototypes in various industrial sectors. Selective laser sintering enables the production of highly precise and detailed parts and is one of the most reliable technologies in the field of powder bed fusion. It uses a process in which the powder is heated slightly below its melting point and selectively sintered layer by layer by a laser. Unsintered powder is collected and reused, which avoids waste and underlines the sustainable nature of this technology.

Until now, polyamide has been the most popular material for SLS, often enriched with aluminum, glass or graphite to improve the properties of the end products. However, the RECYPPOWDER project represents an opportunity to develop a disruptive product that promotes the circular economy and sustainability. Notably, there has been no commercial polymer powder made from recycled polypropylene for SLS.

The research focuses on the formulation and development of copolymers from different blending ratios of commercial and recycled polypropylene to meet the necessary requirements for laser processing. The extent to which the shipping of parts can be replaced by the transmission of print data to reduce the CO2 footprint is also being investigated.

Andaltec contributes to the selection of polypropylene blends, investigates the processability with compatibilizers for laser sintering and characterizes the material. The aim of the RECYPPOWDER project is to have a significant impact on the additive manufacturing industry and to promote sustainability and the circular economy.