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Towards Sustainable 3D Printing: Recycled, Bio-Based and Functionalized Materials for Wireless Devices

21 Nov 2025

This study presents a comprehensive investigation into the dielectric properties of thermoplastic polymer materials used in 3D printing, with particular emphasis on their applicability in reconfigurable antenna systems. A dedicated dielectric property database was developed for a broad spectrum of commercially available filaments, enabling precise modeling and design of 3D-printed microwave structures. Special attention was given to recycled polylactic acid (PLA), with repeated thermal processing cycles performed to evaluate their influence on dielectric performance, highlighting both the potential and limitations of material reuse in high-frequency applications.

This research also explores the application of commercially available PLA composites enhanced with natural biofillers in the design of overlays for electronically steerable parasitic array radiator (ESPAR) antennas. These biodegradable composites offer favorable dielectric characteristics while contributing to environmental sustainability and design flexibility.

To further tailor dielectric properties and support the miniaturization of ESPAR antenna components, ASA and ABS materials were functionalized with ceramic powder admixtures. The incorporation of ceramic fillers enabled controlled tuning of the dielectric constant, expanding the range of functional 3D printing materials suitable for advanced microwave system applications.

The results demonstrate the viability of integrating additive manufacturing with materials engineering to develop sustainable, reconfigurable, and miniaturized components for next-generation wireless communication technologies. 

The project is co-funded by the European Union (SUSTRONICS project). This project is supported by the Key Digital Technologies Joint Undertaking and its members under grant agreement 101112109, including top-up funding by the Netherlands, Austria, Germany, Spain, Finland, France, Latvia, Poland, and Sweden.

Speaker: Bartosz Kamecki, IT specialist, Gdańsk University of Technology