Exploring the Potential of 3D Printing Technology for Sustainable Plastic Roads: A Preliminary Investigation

Abstract

The urgency of climate change has highlighted the need for sustainable road construction materials, replacing the conventional asphalt, which significantly contributes to global warming and the urban heat island effect. With this in mind, the construction of the world’s first 30-m plastic road in Zwolle, Netherlands, in 2018, opened the door for novel plastic applications as paving materials. However, its application is currently still limited to sidewalks and light-load cycling lanes. The feasibility of utilizing 3D printing technology to provide the necessary structural design flexibility for the production of plastic pavement modules that can withstand heavy traffic and extreme weather conditions was examined in this preliminary study. The suitability of six plastic materials (PLA, PETG, ABS, TPU, Nylon, and polycarbonate) for 3D printing was evaluated. Polylactic acid (PLA), and polyethylene terephthalate glycol (PETG) were identified as the most suitable materials for this study. Three small-scale structural systems, namely hollow modular with plastic columns, hollow modular with solid plastic cones, and hollow modular with X-bracing, were designed and successfully printed using the adopted materials and a 3D printer. The developed systems were subsequently subjected to compression testing to assess their structural performance under heavy traffic loads and demonstrate the feasibility of the concept. The results showed that the PLA conic structural system was effective and exhibited the highest compression strength, while the PETG conic system exhibited ductile behavior with superior thermal stability. The study suggests that the hybrid system of PLA and PETG materials may improve the overall performance, combine flexibility and strength, and potentially improve the resistance to extreme weather and heavy traffic. These findings prove that 3D printing technology has the potential to revolutionize the road construction industry and provide more sustainable solutions for infrastructure development.