Mechanically sustainable and primary recycled thermo-responsive ABS–PLA polymer composites for 4D printing applications: Fabrication and studies

3D printing is one of the plastic recycling processes that deliver a mechanically sustainable product and may be used for 4D printing applications, such as self-assembly, sensors, actuators, and other engineering applications. The success and implementation of 4D printing are dependent on the tendency of the shape memory with the action of external stimuli, such as heat, force, fields, light, and pH. Acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) are the most common materials for fused filament fabrication-based 3D printing processes. However, the low-shaped memory tendency on heating and weaker and less rigidity of ABS limit the application domains. PLA is an excellent responsive behavior when the action of heat has high stiffness. The incorporation of PLA into ABS is one of the solutions to tune the shape memory effect for better applicability in the 4D printing domain. In this study, the primary recycled PLA was incorporated into the primary recycled ABS matrix from 5 to 40% (weight%), and composites were made by extrusion in the form of cylindrical filaments for 4D printing. The tensile and shape memory properties of the recycled ABS–PLA composites were investigated to select the best combination. The results of the study were supported by fracture analysis by shape memory analysis, scanning electron microscopy, and optical microscopy. This study revealed that the prepared ABS–PLA-based composites have the potential to be applied in self-assembly applications.