Today, plastics are ubiquitous in everyday life, problem solvers of modern technologies, and crucial for sustainable development. Yet the surge in global demand for plastics of the growing world population has triggered a tidal wave of plastic debris in the environment. Moving from a linear to a zero‐waste and carbon‐neutral circular plastic economy is vital for the future of the planet. Taming the plastic waste flood requires closing the carbon loop through plastic reuse, mechanical and molecular recycling, carbon capture, and use of the greenhouse gas carbon dioxide. In the quest for eco‐friendly products, plastics do not need to be reinvented but tuned for reuse and recycling. Their full potential must be exploited regarding energy, resource, and eco‐efficiency, waste prevention, circular economy, climate change mitigation, and lowering environmental pollution. Biodegradation holds promise for composting and bio‐feedstock recovery, but it is neither the Holy Grail of circular plastics economy nor a panacea for plastic littering. As an alternative to mechanical downcycling, molecular recycling enables both closed‐loop recovery of virgin plastics and open‐loop valorization, producing hydrogen, fuels, refinery feeds, lubricants, chemicals, and carbonaceous materials. Closing the carbon loop does not create a Perpetuum Mobile and requires renewable energy to achieve sustainability.

A polyolefin with certified biocompatibility according to USP class VI was used by our group as feedstock for filament-based 3D printing to meet the highest medical standards in order to print personal protective equipment for our university hospital during the ongoing pandemic. Besides the chemical resistance and durability, as well as the ability to withstand steam sterilization, this polypropylene (PP) copolymer is characterized by its high purity, as achieved by highly efficient and selective catalytic polymerization. As the PP copolymer is suited to be printed with all common printers in fused filament fabrication (FFF), it offers an eco-friendly cost–benefit ratio, even for large-scale production. In addition, a digital workflow was established focusing on common desktop FFF printers in the medical sector. It comprises the simulation-based optimization of personalized print objects, considering the inherent material properties such as warping tendency, through to validation of the process chain by 3D scanning, sterilization, and biocompatibility analysis of the printed part. This combination of digital data processing and 3D printing with a sustainable and medically certified material showed great promise in establishing decentralized additive manufacturing in everyday hospital life to meet peaks in demand, supply bottlenecks, and enhanced personalized patient treatment.