In recent years, plastics recycling has become one of the leading environmental and waste management issues. Along with the main advantage of plastics, which is undoubtedly their long life, the problem of managing their waste has arisen. Recycling is recognised as the preferred option for waste management, with the aim of reusing them to create new products using 3D printing. Additive manufacturing (AM) is an emerging and evolving rapid tooling technology. With 3D printing, it is possible to achieve lightweight structures with high dimensional accuracy and reduce manufacturing costs for non-standard geometries. Currently, 3D printing research is moving towards the production of materials not only of pure polymers but also their composites. Bioplastics, especially those that are biodegradable and compostable, have emerged as an alternative for human development. This article provides a brief overview of the possibilities of using thermoplastic waste materials through the application of 3D printing, creating innovative materials from recycled and naturally derived materials, i.e., biomass (natural reinforcing fibres) in 3D printing. The materials produced from them are ecological, widely available and cost-effective. Research activities related to the production of bio-based materials have gradually increased over the last two decades, with the aim of reducing environmental problems. This article summarises the efforts made by researchers to discover new innovative materials for 3D printing.

In the interest of environmental protection, attention should be paid to improving energy efficiency, through the use of appropriate insulations. They can be used in the construction industry, for plastic window frames, and the thermal insulation of buildings. It is also possible to use these materials in the electronics industry, for hermetic casings of devices, in the aviation industry, as well as in the food industry, as collective packaging for frozen food. The technology of using additive 3D printing to create prototype insulating materials made of plastic is proposed in this article. Multi-layer materials, with quadrangle, hexagonal, and triangle closures were designed and printed. A mathematical model was developed, and then experimentally verified. Quadrangle and hexagonal structures were shown to be useful, and triangle structures to be of little use. The optimal size of closure was determined to be 10 mm, with no convection, and 6 mm, with possible convection. The lowest thermal conductivity of the insulation was 0.0591 W/(m·K) for 10 mm single-layer quadrangle and hexagonal closures with an insulation density of 180 kg/m³.

In just a few short years, the additive manufacturing (AM) technology known as 3D printing has experienced intense growth from a niche technology to a disruptive innovation that has captured the imagination of mainstream manufacturers and hobbyists alike. The purpose of this article is to introduce the use of 3D printing for specific applications, materials, and manufacturing processes that help to optimize heat transfer in heat exchangers, with an emphasis on sustainability. The ability to create complex geometries, customize designs, and use advanced materials provides opportunities for more efficient and stable heat transfer solutions. One of the key benefits of incremental technology is the potential reduction in material waste compared to traditional manufacturing methods. By optimizing the design and structure of heat transfer components, 3D printing enables lighter yet more efficient solutions and systems. The localized manufacturing of components, which reduces the need for intensive transportation and associated carbon emissions, can lead to reduced energy consumption and improved overall efficiency. The customization and flexibility of 3D printing enables the integration of heat transfer components into renewable energy systems. This article presents the key challenges to be addressed and the fundamental research needed to realize the full potential of incremental manufacturing technologies to optimize heat transfer in heat exchangers. It also presents a critical discussion and outlook for solving global energy challenges through innovative incremental manufacturing technologies in the heat exchanger sector.

This paper focuses on the analysis of the thermal properties of prototype insulation structures produced using SLS and SLA additive technologies. There is a noticeable lack of analysis in the scientific literature regarding the geometry of 3D-printed structures in terms of their thermal properties. The aim of this paper was to analyze printed samples of prototype thermal insulation composite structures and their potential for use in building applications. The research material consisted of closed and open cell foams of varying structural complexity. Increasing the complexity of the composite core structure resulted in a statistically significant decrease in the value of the thermal conductivity coefficient λ and the heat transfer coefficient U, and an increase in the thermal resistance Rc. The experimental results showed that the geometric structure of the air voids in the material is a key factor in regulating heat transfer. The control of porosity in materials produced by additive technology can be an effective tool for designing structures with high insulation efficiency. The best performance of the prototype materials produced by the SLS method was a three-layer cellular composite with a gyroid core structure. It was also shown that the four-layer gyroid structure panels with an outer layer of metallized polyethylene film produced using 3D SLA printing had the best thermal insulation. As a result, the analysis confirmed the possibility of producing energy-efficient insulation materials using 3D printing. These materials can be used successfully in construction and other industries. Further research will significantly improve the quality, accuracy, and speed of printing insulation materials, reduce the negative impact on the natural environment, and develop intelligent adaptive solutions.

Packaging and packaging technology constitute a pivotal industry deeply intertwined with our daily lives and prevalent in various settings, including grocery stores, supermarkets, restaurants, and pharmacies. The industry is constantly evolving thanks to technological advances. This article delves into the dynamic landscape of 3D printing in packaging, exploring its profound implications and potential. While this article highlights the advantages of traditional packaging approaches, it also highlights the many benefits of 3D printing technology. It describes how 3D printing enables personalization, rapid prototyping, and low-cost production, streamlining packaging design and manufacturing processes. Offering innovative solutions in design, functionality, and accessibility, the potential of 3D printing in packaging is promising.

This paper focuses on the search for novel insulating structures, and the generation of them by means of a state-of-the-art manufacturing method—3D printing. Bionic structures, which are successfully used in many branches of technology, were chosen as the source of inspiration for the research. The paper presents a design of spatial structures with a gyroid infill (e.g., TPMS), the shape of which reflects the bionic structure of the inside of a bone. For SLS printed single- and multi-layered structures, the design value of the thermal conductivity coefficient was determined through measurements and calculations. A statistical analysis was carried out to determine the effect of the direction of heat flow, as well as the internal structure and layering of the prototype materials, on the values of the thermal conductivity coefficient and the thermal resistance coefficient. On the basis of the multicriteria analysis, the composite’s optimal composition according to the adopted optimization criteria was determined. The lowest possible thermal conductivity of the insulation was equal to 0.033 W/(m·K). The highest possible thermal resistance was equal to 0.606 m²·K/W. Thermal insulation made of the prototype insulating partitions with a gyroidal structure is characterized by good insulating parameters.