Circular Economy in Polymer 3D Printing

Tune in as host Björn chats with plastic materials expert Sophie Mulsant-Kern from Arkema about the important world of circular economy. In this episode, they'll break down the procedure and benefits of a global take-back program for used 3D printing polymer powder and parts. The positive environmental impact of this initiative is backed by a professional Life Cycle Assessment (LCA) which she'll also share. Manufacturers, listen up — you'll learn how easy it is to join the movement and make a difference! Whether you're a sustainability enthusiast or a curious listener, this episode promises to be both informative and inspiring. Tune in and be part of the reutilization revolution!

Links in this episode:

• Join Virtucycle® Recycling Program | Arkema High Performance Polymers

What is BLUEPRINT for Responsible Manufacturing?

Today’s environmental and social challenges demand action. As technology experts, we are committed to accelerating the world’s transition to Responsible Manufacturing with industrial 3D printing. This podcast delivers insights into projects, concepts, and ideas on how to make Responsible Manufacturing the new normal. Meet Björn, our Head of Sustainability, and his guests. from customers, suppliers, research institutes, NGOs, and EOS colleagues. Join us on this exciting journey of exploring Responsible Manufacturing!

Björn: 00:31

Hello, and welcome to episode number 10 of Blueprint, our video blog for responsible manufacturing. My name is I'm heading the sustainability team at EOS, and I'm the host of this video blog. Today, we're in Italy. We're here at AG Plus in Casalbotano. And I'm already very excited to meet, Sophie Muson Caron, who is the global sourcing and sales manager, high performance polymers at Akema.

Björn: 00:57

In this episode today, you will learn how circularity is made possible, how the powder take back program, Vertucycle, is working, what the customers request in terms of powder reutilization, and also we will talk about the results of a scientific study we made together in order to prove the benefits of this program. Sophie, thank you, for having us, and welcome, to blueprint.

Sophie: 01:29

Thank you very much, Bjorn. And I'm very pleased to welcome you in, our site from AGI Place in Casa Buetano, where the summertime, welcome you as well.

Björn: 01:38

Thank you. Before we start into the, into the conversation, can you please shortly introduce yourself and your role?

Sophie: 01:46

Okay. So from my own person, so I'm Sophie, and I'm working in a sourcing, for Agi Plates. I mean, sourcing of different kind of material from high performance polymer, like a long chain polyamide, TPE, and also PVDF. And I have also another cap, which is also of the sales side, where I'm taking care of the selling of this solar cycling product. For me, 3 d printing is not something that is totally unknown because I spent the last 7 years working, as the European sales, for Powerbed Fusion product.

Sophie: 02:20

So I'm I'm very, very happy to, be with through my new position to have a still a step with the 3 d printing.

Björn: 02:26

Okay. And we're happy as well. So, to start off, what are the challenges of, of your customers in terms of powder regionalization, powder handling?

Sophie: 02:36

Globally speaking then, when we are talking about, technical high-tech performance polymers, the product is recyclable. So there is no no point on that. However, unlike the commodity plastic, where you have all the chain of collection chain, for this kind of polymers, we we it doesn't exist. So we there is no one on the market who is able to collect, to, compound and and resell after, recycling product on the market. So and it's where AGI plus step in.

Sophie: 03:07

We are able to make the collection. We are able to recompound, to make granule again, and to resell high value, granules with a high recycled content.

Björn: 03:18

Mhmm. And this program is called VertuCycle. And, how long is it, how long has it been running? And can you tell us a little bit about what you have achieved so far?

Sophie: 03:29

Agipass is quite a long story. The company has been, created in 90, 94. The collaboration, we will celebrate this year 13 years, so we are I'm proud to announce that. We have a long collaboration, we start the virtual cycle with, AGI Place in 2019. And after 2021, Arkema's acquisition of AGI Place, we, extended, the offer, to, 3 d printing and also PVDF product.

Björn: 03:59

Mhmm. And, can you tell us a bit more about the program? So how does it work?

Sophie: 04:04

Companies are contacting us, can be private service provider or, or even OEM. And, they send us, here in Casa Builano their sample. So it can be, either powder or part or both. And then it's gonna be here we have glass test here. And, if the property of the product are is fit are fitting with our expectation, then, they they will receive a green light from us.

Sophie: 04:31

And then the our supplier have just have to take care about the suitable packaging and, put the packaging outside, and then we are coming to collect. Mhmm. After the collection, the product will come here in Casa Bu Tunnel, where we, we will do a recycling step process, and from the powder and from the pot, we're gonna make some, some granules. And these granules are recycled, and then this granule will be used in formulation because formulation is, the blood of our work, to be able then to generate, granules that can be used in a high demanding application.

Björn: 05:13

And I mean, our audience is mainly from the 3 d printing, industry, I guess, but this program is not limited to 3 d printing. Right? It's open to to everyone, also, other customers.

Sophie: 05:25

Yes. We have a very bright range, the only condition is that, if we are very happy to have a collaboration with people, are we using launching polyamide p 11, p 12, TPE part, and and also the, Fluoropolymer PVDF.

Björn: 05:39

Mhmm.

Sophie: 05:39

So we are everybody are welcome to work together.

Björn: 05:41

And why would customers, come to you? Where would companies come to you to do that? I mean, what are the the benefits they have?

Sophie: 05:48

First, I think it's, and it's normal in our business life, the economical perspective. Mhmm. What was a burden before with the disposal and then destruction cost is becoming an economical asset. So it's getting a value for the one who wants to disposal the powders and the part because they, they get money for that. So, it's a win situation for them.

Björn: 06:16

So, besides the purely commercial benefit, are there any environmental benefits as well?

Sophie: 06:22

When we step back, we can we can say that everybody is is, has the benefits of the Vitru cycle. So, the company, who generate the used powder and and the part, is for them a benefit instead of a burden. Mhmm. Then Arkema, we are very happy to have this this source of of material, new material on high quality. And and then at the end, the end customer will will buy the granules.

Sophie: 06:54

They will have recycled granules with the almost 1 81% of of CO2 emission less. So, we are all benefit

Björn: 07:04

on all of that. Mhmm. And, I mean, we, as US, we're always very committed to power take back, as well. So it's very important, for us as well. At the other hand, we also know it is sometimes a bit, complicated.

Björn: 07:19

You need to look at many things in in very details. Also, sometimes there might be doubts about transportation of used material, to Argiplast, for example, and if if there is still, a benefit. And that's why together we made a a life cycle assessment Do you look or have a deeper look at this? Can you share about the setup of this analysis? So how was it made?

Sophie: 07:44

The conviction that on on the unsustainable point of view, that, virtuous cycle have a lot of benefits was definitely show for all of us. What we decide is to bring fact and scientific and qualitative and quantitative fact, for that. For this reason, you, US, and and, and, Crown Office Institute, we decided to launch, LCA analysis to compare the, the reutilization of this, PA 12, used powder coming from the, AM industry. And by reprocessing it in granules on p l PA 12, comparing to, the current situation, this incineration.

Björn: 08:30

Mhmm.

Sophie: 08:30

And, production of, primary PA 12.

Björn: 08:34

Mhmm.

Sophie: 08:35

In terms of scale that we found the Vitrecycle, what makes the more sense is the, is the impact on climate impact. So, the carbon emission is what we we were focused on.

Björn: 08:47

And and and now, we're eager to hear what the results were of this.

Sophie: 08:51

So comparing the conventional disposal and and the conventional, production of primary, material, we, find out that we have a saving of up to 7.2, kilogram, c o two equivalent, which is very important. And we've seen that the main, the main gain is at the production of the of the the the hurdle was, the the main gain is the primary PA 12, production. Mhmm. And and even, the the scope, and we have studied also all the factor and transport is belong to this, this scope. We we noticed that the impact was not that high, even that the product is coming from US and ASEAN, it was not

Björn: 09:36

the more. And now we're talking, let's just talk about the recycled granules. I mean, what are customers doing with that then?

Sophie: 09:45

So, we have a longer story in recycling and our our really core business is is to formulate new granules. So we are aiming a consistency quality, high quality of our recycling granules. We have a lot of application, in automotive, in industrial, in consumer. I also bring something just to show you, at least an example. It's a tennis racket from Wilson, and, the bumpers is made of, recycled polyamide.

Sophie: 10:22

Mhmm. So that's an example of of application we may have.

Björn: 10:26

And so we're already close to the end, Sophie. But what is your personal vision for AM and reutilization of powders, let's say, within the next 3 to 5 years?

Sophie: 10:41

From my experience, we know that the, the powder, used powder is a a hurdle in the industry. So, I see that, because of the cooperation between, between our company, for example, that we try to reduce as most as possible the use, the used powder at the end, so by, playing with the refresh rate that targets. So I've seen much more parts produced than powders. And for me, it's the the the goal of this will be that we can convert all the part after, not at granule for the injection or extrusion industry, but this part can be reused as powder for the 3 d, for the 3 d printing. That will be, for me, a big step.

Björn: 11:22

Okay. We're looking forward to that, because that would also be of interest for us, of course. Thank you so much, Sophie for hosting us and for providing these these these insights. And if you have any questions or comments or maybe ideas for future topics we should cover, just leave them here, in the notes and, in the comments and as always, stay responsible.