--- title: "Recycled PETG Powers Carbon Fiber Filaments for 3D Printing" id: "8592" type: "post" slug: "recycled-petg-powers-carbon-fiber-filaments-for-3d-printing" published_at: "2025-07-12T17:12:57+00:00" modified_at: "2025-07-10T21:35:17+00:00" url: "https://www.plasticsengineering.org/2025/07/recycled-petg-powers-carbon-fiber-filaments-for-3d-printing-008592/" markdown_url: "https://www.plasticsengineering.org/2025/07/recycled-petg-powers-carbon-fiber-filaments-for-3d-printing-008592.md" excerpt: "In a recent study published in Polymer Composites, researchers led by Sütcüler et al. unveiled a lab-scale process to manufacture continuous carbon fiber (CCF) filaments using recycled PETG (rPETG)." taxonomy_category: - "3D Printing/Additive Manufacturing" - "Aerospace" - "Automotive & Transportation" - "Circular Economy" - "Composites" - "Editor's Choice Technical Paper" - "Industry" - "Materials" - "Process" - "Recycling" - "Sustainability" taxonomy_post_tag: - "3D Printing" - "CCF" - "Composite Filament" - "continuous carbon fiber" - "Fiber Type" - "fused filament fabrication" - "lower carbon footprints" - "PETG" - "Polymer Composites" - "Recycled PETG" - "recycled thermoplastics" - "rPETG" --- [Home](https://www.plasticsengineering.org/) » [News](https://www.plasticsengineering.org/news/) » [Materials](https://www.plasticsengineering.org/c/materials/) » [Composites](https://www.plasticsengineering.org/c/materials/composites/) » Recycled PETG Powers Carbon Fiber Filaments for 3D Printing # Recycled PETG Powers Carbon Fiber Filaments for 3D Printing Conventional techniques for producing carbon fiber-reinforced filaments often result in poor fiber alignment and low impregnation efficiency. To address this, the researchers developed a direct melt impregnation process that streamlines production and enhances the filaments' structural integrity.### In a recent study published in *Polymer Composites*, researchers led by Sütcüler et al. unveiled a lab-scale process to manufacture continuous carbon fiber (CCF) filaments using recycled PETG (rPETG). ## Redefining Composite Filament Manufacturing Traditional methods of producing carbon fiber-reinforced filaments for 3D printing often suffer from poor fiber alignment and inefficient impregnation. In response, the researchers designed a direct melt impregnation process that simplifies filament production and improves structural quality. **You can also read:** [Closing the Carbon Fiber Loop.](https://www.plasticsengineering.org/2023/11/closing-the-carbon-fiber-loop-002421/) Schematic demonstration of the impregnation area (left), and impregnation of porous fiber bed (right). Courtesy of [Lab-scale manufacturing of thermoplastic matrixcontinuous carbon fiber filaments for additive manufacturing: Melt impregnation, properties of the filaments and its printed composites.](https://doi.org/10.1002/pc.29241) The key innovation lies in eliminating the rounding step, which is commonly used to shape filaments but often introduces fiber misalignment and S-shaped distortion. By removing this step and using a custom conical pin system, the researchers achieved uniform fiber spread and enhanced impregnation with the polymer matrix. ## Using Recycled PETG as a Matrix This study focuses on recycled PETG, a thermoplastic offering excellent mechanical strength and processability for composite manufacturing applications. The researchers showed that rPETG flows efficiently at 260°C, which makes it well-suited for direct melt impregnation of carbon fibers. Moreover, using rPETG reduces the dependency on virgin plastics and aligns with sustainable design practices in modern material development. Additionally, this recycling approach diverts plastic waste from landfills and channels it into durable, high-performance composite materials. As a result, integrating recycled polymers into structural components creates circular opportunities in aerospace, automotive, and electronic product design. Continuous fiber filament production system with horizontal (1) and vertical (2) impregnation pins design.Courtesy of [Lab-scale manufacturing of thermoplastic matrixcontinuous carbon fiber filaments for additive manufacturing: Melt impregnation, properties of the filaments and its printed composites.](https://doi.org/10.1002/pc.29241) Continuous fiber filament production system with horizontal (1) and vertical (2) impregnation pins design.Courtesy of [Lab-scale manufacturing of thermoplastic matrixcontinuous carbon fiber filaments for additive manufacturing: Melt impregnation, properties of the filaments and its printed composites.](https://doi.org/10.1002/pc.29241) ## Fiber Type Matters: Sizing and Performance To evaluate performance, the team tested three types of carbon fibers with different sizing chemistries and mechanical properties. Results showed that the type of fiber sizing significantly influences tensile strength, fuzz formation, and overall quality of the filament. Notably, CF-2, a rigid carbon fiber with suitable sizing, achieved a tensile strength translation of approximately 84%, outperforming CF-1, a more flexible fiber. The right fiber and sizing combination ensured strong interfacial bonding, minimal fiber breakage, and excellent mechanical performance. Tensile strength of CCFs produced with different carbon fibers. Courtesy of [Lab-scale manufacturing of thermoplastic matrixcontinuous carbon fiber filaments for additive manufacturing: Melt impregnation, properties of the filaments and its printed composites.](https://doi.org/10.1002/pc.29241) ## Ready for 3D Printing The final filaments were successfully processed in fused filament fabrication (FFF) 3D printers to create test samples. Mechanical testing, including interlaminar shear strength (ILSS) and dynamic mechanical analysis (DMA), revealed that filaments produced with CF-2 had 24.3% higher ILSS compared to CF-3. Moreover, DMA results showed improved damping and energy absorption, essential for applications requiring vibration resistance and fatigue durability. SEM imaging confirmed better interfacial adhesion and reduced fiber damage in well-impregnated filaments. ## Sustainable Impact and Industry Potential This study carries significant implications for both composite manufacturing and plastic waste management. By enabling the use of recycled thermoplastics in high-performance, continuous fiber composites, this approach merges sustainability with structural integrity. Industries such as aerospace, defense, and automotive—which rely heavily on strong, lightweight materials—could adopt this technology to lower carbon footprints without compromising quality. The direct melt impregnation technique is scalable, cost-effective, and compatible with existing additive manufacturing platforms. In addition, it represents a viable pathway for converting industrial plastic waste into structural components, supporting circular economy goals and reducing landfill dependency. ## Composites Manufacturing Landscape Sütcüler and colleagues developed a practical method to produce composite filaments that combine strong mechanical performance with recyclability. Their research emphasizes the need for careful material selection, optimized processing, and sustainable design in future additive manufacturing practices. Moreover, as industries transition toward cleaner technologies, such innovative methods become essential to advancing circular, closed-loop production systems. Consequently, this approach will influence how we design, manufacture, and reuse high-performance materials in an increasingly sustainability-focused world. By **[Juliana Montoya](https://www.plasticsengineering.org/author/jmontoyaplasticsengineering-org/)** | July 12, 2025 [https://www.plasticsengineering.org](https://www.plasticsengineering.org) ##### [Juliana Montoya](https://www.plasticsengineering.org/author/jmontoyaplasticsengineering-org/) [Website](https://www.plasticsengineering.org) | [+ postsBio ⮌](#) ### Other posts you could read [April 6, 2026Thermotropic LCEs Power Soft Robotics](https://www.plasticsengineering.org/2026/04/thermotropic-lces-power-soft-robotics-010984/) [April 22, 2026Beyond Flaps: How Composite Skins Enable Morphing Wing Design](https://www.plasticsengineering.org/2026/04/beyond-flaps-how-composite-skins-enable-morphing-wing-design-010950/) [May 1, 2026High-Viscosity Photopolymers Transform Additive Manufacturing](https://www.plasticsengineering.org/2026/05/high-viscosity-photopolymers-transform-additive-manufacturing-011153/) [April 29, 2026Renewable Functional Coatings for Advanced Applications](https://www.plasticsengineering.org/2026/04/renewable-functional-coatings-for-advanced-applications-011134/) [April 27, 2026Nanocomposite Films from Car Bumper Waste](https://www.plasticsengineering.org/2026/04/nanocomposite-films-from-car-bumper-waste-011041/) [April 30, 2026Upcycling Polyolefins into Jet Fuel Components](https://www.plasticsengineering.org/2026/04/upcycling-polyolefins-into-jet-fuel-components-011138/) [April 21, 2026Flame-Resistant Polymers for Space Safety and Aerospace Use](https://www.plasticsengineering.org/2026/04/flame-resistant-polymers-for-space-safety-and-aerospace-use-011162/) [April 9, 2026RecyQMeter: Quantifying Recycled Plastic Quality](https://www.plasticsengineering.org/2026/04/recyqmeter-quantifying-recycled-plastic-quality-010917/) ## Share Your Thoughts [Cancel reply](/2025/07/recycled-petg-powers-carbon-fiber-filaments-for-3d-printing-008592/#respond) - [https://twitter.com/share?url=https://www.plasticsengineering.org/?p=8592&text=Recycled+PETG+Powers+Carbon+Fiber+Filaments+for+3D+Printing&via=Plastics_Mag](https://twitter.com/share?url=https://www.plasticsengineering.org/?p=8592&text=Recycled+PETG+Powers+Carbon+Fiber+Filaments+for+3D+Printing&via=Plastics_Mag) - [https://www.facebook.com/sharer.php?u=https://www.plasticsengineering.org/?p=8592&t=Recycled+PETG+Powers+Carbon+Fiber+Filaments+for+3D+Printing](https://www.facebook.com/sharer.php?u=https://www.plasticsengineering.org/?p=8592&t=Recycled+PETG+Powers+Carbon+Fiber+Filaments+for+3D+Printing) - [https://www.linkedin.com/shareArticle?mini=true&url=https://www.plasticsengineering.org/?p=8592&title=Recycled%20PETG%20Powers%20Carbon%20Fiber%20Filaments%20for%203D%20Printing&summary=In+a+recent+study+published+in+Polymer+Composites%2C+researchers+led+by+S%C3%BCtc%C3%BCler+et+al.+unveiled+a+lab-scale+process+to+manufacture+continuous+carbon+fiber+%28CCF%29+filaments+using+recycled+PETG+%28rPETG%29.&source=Plastics+Engineering](https://www.linkedin.com/shareArticle?mini=true&url=https://www.plasticsengineering.org/?p=8592&title=Recycled%20PETG%20Powers%20Carbon%20Fiber%20Filaments%20for%203D%20Printing&summary=In+a+recent+study+published+in+Polymer+Composites%2C+researchers+led+by+S%C3%BCtc%C3%BCler+et+al.+unveiled+a+lab-scale+process+to+manufacture+continuous+carbon+fiber+%28CCF%29+filaments+using+recycled+PETG+%28rPETG%29.&source=Plastics+Engineering) - [https://www.reddit.com/submit?url=https://www.plasticsengineering.org/?p=8592&title=Recycled+PETG+Powers+Carbon+Fiber+Filaments+for+3D+Printing](https://www.reddit.com/submit?url=https://www.plasticsengineering.org/?p=8592&title=Recycled+PETG+Powers+Carbon+Fiber+Filaments+for+3D+Printing) - [/cdn-cgi/l/email-protection#241b5751464e4147501974484557504d475704614a434d4a4141564d4a430409047641475d47484140047461706304744b5341565704674556464b4a04624d46415604624d484549414a505704424b560417600474564d4a504d4a4302464b405d194c505054571e0b0b5353530a54484557504d4757414a434d4a4141564d4a430a4b56430b1b54191c111d16](/cdn-cgi/l/email-protection#241b5751464e4147501974484557504d475704614a434d4a4141564d4a430409047641475d47484140047461706304744b5341565704674556464b4a04624d46415604624d484549414a505704424b560417600474564d4a504d4a4302464b405d194c505054571e0b0b5353530a54484557504d4757414a434d4a4141564d4a430a4b56430b1b54191c111d16) - [#comments](#comments)