Innovating a Sustainable Future: Upcycling Local Waste with Additive Manufacturing Technologies

This research project upcycling waste plastics and locally sourced agricultural waste into advanced composite materials using additive manufacturing technologies. The primary objectives include (1) optimizing FDM parameters for composites made from recycled plastics—specifically low-density polyethylene (LDPE) and polystyrene (PS)—blended with agricultural fibers, (2) enhancing the printability and mechanical properties of these composites, and (3) conducting a Life Cycle Assessment (LCA) to quantify environmental benefits. Systematic optimization of FDM parameters, such as extrusion temperature, print speed, and layer height, will produce composites with optimized strength, durability, and material distribution. The project will also conduct an LCA using GaBi software to assess the environmental impacts of 3D-printed composites versus traditional methods.. Expected outcomes include optimized FDM filaments, continuous fiber composites, a robust environmental impact assessment, and a scalable framework for recycling plastic and agricultural waste into valuable manufacturing materials. This project aligns with Qatar’s circular economy and environmental goals, benefiting sectors like automotive, construction, and consumer goods. Through high-level FDM optimization, the project establishes AM as a sustainable, low-waste manufacturing solution, positioning Qatar as a leader in sustainable additive manufacturing and circular economy practices.

Hamad Bin Khalifa University (HBKU)