This review article gathers the most recent recycling technologies for thermoset and thermoplastic polymers. Results about existing experimental procedures and their effectiveness are presented. For thermoset polymers, the review focuses mainly on fibre-reinforced polymer composites, with an emphasis on epoxy-based systems and carbon/glass fibres as reinforcement, due to the environmental concerns of their end-of-life management. Thermal processes (fluidised bed, pyrolysis) and chemical processes (different types of solvolysis) are discussed. The most recent combined processes (microwave, steam, and ultrasonic assisted techniques) and extraordinary recycling attempts (electrochemical, biological, and with ionic liquids) are analysed. Mechanical recycling that leads to the downgrading of materials is excluded. Insights are also given for the upcycling methodologies that have been implemented until now for the reuse of fibres. As for thermoplastic polymers, the most state-of-the-art recycling approach for the most common polymer matrices is presented, together with the appropriate additivation for matrix upcycling. Mechanical, chemical, and enzymatic recycling processes are described, among others. The use of fibre-reinforced thermoplastic composites is quite new, and thus, the most recent achievements are presented. With all of the above information, this extensive review can serve as a guide for educational purposes, targeting students and technicians in polymers recycling.

The COVID-19 pandemic instigated massive production of critical medical supplies and personal protective equipment. Injection moulding (IM) is considered the most prominent thermoplastic part manufacturing technique, offering the use of a large variety of feedstocks and rapid production capacity. Within the context of the European Commission-funded imPURE project, the benefits of IM have been exploited in repurposed IM lines to accommodate the use of nanocomposites and introduce the unique properties of nanomaterials. However, these amendments in the manufacturing lines highlighted the need for targeted and thorough occupational risk analysis due to the potential exposure of workers to airborne nanomaterials and fumes, as well as the introduction of additional occupational hazards. In this work, a safety-oriented failure mode and effects analysis (FMEA) was implemented to evaluate the main hazards in repurposed IM lines using acrylonitrile butadiene styrene (ABS) matrix and silver nanoparticles (AgNPs) as additives. Twenty-eight failure modes were identified, with the upper quartile including the seven failure modes presenting the highest risk priority numbers (RPN), signifying a need for immediate control action. Additionally, a nanosafety control-banding tool allowed hazard classification and the identification of control actions required for mitigation of occupation risks due to the released airborne silver nanoparticles.

Nanoparticles are being used in novel applications of the thermoplastics industry, including automotive parts, the sports industry and leisure and consumer goods, which can be produced nowadays through additive manufacturing. However, there is limited information on the health and safety aspects during the production of these new materials, mainly from recycled sources. This study covers the exposure assessment to nano- and micro-size particles emitted from the nanocomposites during the production of filaments for 3D printing through a compounding and extrusion pilot line using recycled (post-industrial) thermoplastic polyurethane (TPU) and recycled polyamide 12 (PA12), which have been also upcycled through reinforcement with iron oxide nanoparticles (Fe₃O₄ NPs), introducing matrix healing properties triggered by induction heating. The assessment protocol included near- and far-field measurements, considering the extruder as the primary emission source, and portable measuring devices for evaluating particulate emissions reaching the inhalable zone of the lab workers. A Failure Modes and Effects Analysis (FMEA) study for the extrusion process line was defined along with a Failure Tree Analysis (FTA) process in which the process deviations, their sources and the relations between them were documented. FTA allowed the identification of events that should take place in parallel (simultaneously) or in series for the failure modes to take place and the respective corrective actions to be proposed (additional to the existing control measures).

Stereolithography (SL) additive manufacturing process provides increased dimensional precision, smooth surface finish and printing resolution range in the order of magnitude of 100 μm, allowing to obtain intricate 3D geometries. The incorporation of ceramic-based inclusions within liquid resins enhances the thermal and mechanical properties of the final 3D printed component while improving the surface finishing of the final parts; in this way, it expands the range of process applications and reduces the post-processing steps. The proposed approach investigates the bulk modification of commercial SLA resins mixed with ceramic powders of Al₂O₃ (grain size 1–10 μm) and SiO₂ (grain size 55–75 nm) aiming to improve 3D printed parts performance in terms of mechanical properties, dimensional stability and surface finishing compared with pure, unmodified resins. The produced materials were used for the development of inserts for injection moulding and were examined for their performance during the injection moulding process. The addition of particles in the nano- and micro-range is being employed to improve parts performance for rapid tooling applications whilst maintaining 3D printing accuracy, thermal and mechanical properties as well as achieving a smooth surface finishing compared with unmodified resins.

The mechanical recycling of styrenic polymers from waste electrical and electronic equipment (WEEE) is often limited by thermomechanical degradation occurring during repeated processing. In this work, the degradation behaviour of acrylonitrile–butadiene–styrene (ABS) recovered from sorted WEEE streams was systematically investigated through multiple extrusion cycles, and the effectiveness of antioxidant stabilization was evaluated. Progressive degradation was assessed by chemical structure, rheological, thermal and mechanical testing, and colorimetric analysis. Repeated processing resulted in increased melt flow, altered viscoelastic behaviour, molecular weight reduction, deterioration of mechanical properties, and discoloration. To mitigate these effects, antioxidant-stabilized compounds were prepared and subjected to identical reprocessing pathways. The addition of antioxidants effectively reduced chain scission, stabilized rheological properties, and limited colour changes during reprocessing. Furthermore, the processability of the optimized recycled ABS is demonstrated through filament extrusion for fused filament fabrication, highlighting its potential for high-value additive manufacturing applications. These results demonstrate that appropriate stabilization strategies can significantly enhance the process stability and recyclability of styrenic polymers from WEEE streams, supporting their use in higher-value applications within a circular economy framework.