This study intends to enhance the mechanical strength of wood–plastic composite selective laser sintering (SLS) parts by using a sustainable composite, peanut husk powder (PHP)/poly ether sulfone (PES) (PHPC). The study aims to address agricultural waste pollution by encouraging the eco-friendly utilization of such waste in SLS technology. To ensure the sintering quality and mechanical properties and prevent deformation and warping during sintering, the thermo-physical properties of PHP and PES powders were analyzed to determine a suitable preheating temperature for PHPC. Single-layer sintering tests were conducted to assess the formability of PHPC specimens with varying PHP particle sizes. The study showed the effects of different PHP particle sizes on the mechanical performance of PHPC parts. The evaluation covered various aspects of PHPC SLS parts, including mechanical strength, density, residual ash content, dimensional accuracy (DA), and surface roughness, with different PHP particle sizes. The mechanical analysis showed that PHPC parts made from PHP particles of ≤0.125 mm were the strongest. Specifically, the density bending strength, residual ash content, tensile, and impact strength were measured as 1.1825 g/cm³, 14.1 MPa, 1.2%, 6.076 MPa, and 2.12 kJ/cm², respectively. Notably, these parameters showed significant improvement after the wax infiltration treatment. SEM was used to examine the PHP and PES powder particles, PHPC specimen microstructure, and PHPC SLS parts before and after the mechanical tests and waxing. Consequently, SEM analysis wholly confirmed the mechanical test results.

Shells, a type of food waste, present a notable challenge in achieving high-value applications in the environmental sector owing to their complex compositions, limited recycling applications, and the environmental impact of improper disposal. This study conducts a comparative analysis of the mechanical properties of five types of natural shells: veined red snail, mussel, oyster, scallop, and green willow clam. Shell powders and polylactic acid (PLA) were used as the inorganic and organic components of shells, respectively. The laser sintering mechanism for forming these components was explored, resulting in the fabrication of five biomimetic shells. Results showed that the flexural strength decreased in the order of veined red snail > mussel > scallop > green willow clam > oyster. The flexural strength values of laser-sintered specimens made from five shell powder/PLA composites corresponded closely to those of their respective shells, with values of 8.6, 8.1, 7.6, 6.9, and 6.1 MPa. These values exceeded those of pure PLA specimens. Furthermore, the compressive load capacity of 3D-printed biomimetic veined red snail parts, 3D-printed biomimetic mussel parts, 3D-printed oyster parts, 3D-printed biomimetic scallop parts, and 3D-printed biomimetic green willow clam parts reached 76.69%, 19.10%, 5.57 times, 26.66%, and 70.46%, of the load capacities of the natural shell counterparts, respectively.

As an aquaculture waste, the veined red snail achieves significant ecological burden reduction through recycling. Compared with polycaprolactone (PCL), it boasts greater environmental and economic advantages. Veined red snail powder with different proportions was added to PCL—a common material for manufacturing bone scaffolds—and laser sintering technology was used to prepare veined red snail powder/PCL composite powder laser-sintered parts. Based on single-factor experiments, the process was optimized using the response surface methodology, and the parts with different veined red snail powder additions were studied. The results show that under the process conditions of laser power 12.25 W, scanning speed 0.7 m s ⁻¹ , scanning spacing 0.14 mm, and layer thickness 0.17 mm, the tensile strength of the laser-sintered part reaches 7.59 ± 0.16 MPa, with an error of 1.93% compared with the model prediction value. Under these process conditions, the laser-sintered parts with different veined red snail powder additions were characterized separately. The addition of shell powder effectively reduces the economic cost of the laser-sintered parts and significantly improves their surface hardness and hydrophilicity. When the addition amount ranges from 0 to 25 wt%, the hardness increases by up to 32.08% relative to pure PCL parts, and the hydrophilicity (contact angle) changes from 87.86 ± 0.53°to 72.58 ± 0.95°(a smaller contact angle indicates better hydrophilicity).

In response to the urgent demand for sustainable materials and manufacturing, this study explores a high-value pathway for converting forestry waste into functional products. This study systematically optimized the binder jetting 3D printing process for wood–plastic composite materials using poplar powder, a renewable and abundantly available forestry waste, as the raw material. Compared with traditional methods, this additive manufacturing approach minimizes material waste and energy consumption, significantly enhancing both material and energy utilization efficiency, thereby providing technical support for green manufacturing. Using the response surface methodology, the optimal combination of process parameters was determined as follows: adhesive saturation of 62.4%, layer thickness of 62.7 μm, printing speed of 58.6 mm/s, and curing time of 49.9 min. Under these conditions, the cured specimen achieved a density of 0.64 g/cm³, a flexural strength of 0.80 MPa, and a tensile strength of 0.69 MPa, demonstrating excellent mechanical performance. The established robust predictive model further validates the feasibility of wood–plastic composites that offer both superior performance and environmental benefits. This study presents a breakthrough solution for the high-value utilization of wood waste, strongly promoting the advancement of sustainable material science and the circular economy.