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The decentralized production associated with material extrusion additive manufacture (MEX) has been proposed as an ideal path to increase the circularity of plastics through direct recycling. Although multiple studies have reported on the 3D printing of various recycled plastics, variability in recycled materials, in particular post-consumer waste, challenges the direct extension of these results into production through MEX. Here, we demonstrate filament fabrication and printing of post-consumer polypropylene (PP), where the PP is sourced from clear, cold drink cups from three large international food service and beverage retail chains to provide well defined plastic waste that is perfectly sorted for recycling. These sources for the recycled PP were selected due to their ready availability to enable the results to be directly applied for hobbyist printing, blow molded products to provide good mechanical performance, and the clarity of the PP that suggests formulation design to minimize the PP crystal size. Despite the similarities in the end use product and their physical appearance, the source for the PP impacted the mechanical properties and the visual appearance of the printed objects. These differences can be directly traced to the rheological properties and oxidative stability of the PP at conditions relevant with the print process. These results clearly illustrate differences in initial formulation design and branding details, even when the product is for the same application, impacts the performance of recycled plastics in AM. The high viscosity associated with the PP from blow molding leads to requirements for higher extrusion temperatures for printing. The combination of high temperature and shear during extrusion process of 3D printing degrades the recycled PP. For circularity with MEX with recycled PP, one needs to consider the evolution in the properties of the polymer. Rheological details of recycled plastics are critical to selection of processing conditions and performance of MEX parts. Reporting of rheological data of recycled plastics and these properties after printing is critical to enable translation towards circular 3D printing of recycled plastics. 

One critical challenge for commercial products manufactured via material extrusion 3D printing is their inferior mechanical properties in comparison to injection molding; in particular, 3D printing leads to weaker properties perpendicular to the plane of the printed roads (z-direction). Here, rapid (≤20 s) post-processing of 3D printed carbon- poly(ether ether ketone) (PEEK) with microwaves is demonstrated to dramatically increase the modulus, such that the z-direction after microwave processing (2.7–3.8 GPa) exhibits a higher elastic modulus than the maximum in any direction for the as-printed part (2.3 GPa). Additionally, the stress at break in the z-orientation is increased by an order of magnitude by microwaves to slign with the stress for other print orientations in the as-printed state. The rapid heating and cooling by coupling of the microwave energy with the carbon filler in the PEEK does not increase the crystallinity of the PEEK, so the increased mechanical properties are attributed to improved interfaces between printed roads. This simple microwave post-processing enables large increases in the elastic modulus of the printed parts and can be tuned by the microwave power. As PEEK is generally difficult to print, these concepts can likely be applied to other commercial engineering plastic filaments that contain carbon or other fillers that are microwave active to rapidly post process 3D printed thermoplastics without requiring modification of the filament with selective placement of microwave absorbers. Additionally, these results demonstrate that the average crystallinity does not necessarily correlate with the strength of 3D printed semicrystalline plastics due to the importance of the details of the interface between adjacent printed roads.