Nowadays 3D printing has excellent potential and attention over the traditional manufacturing technology and has more recycling possibilities. The present study focuses on the conversion of 3D printing raft support waste from the Fused Filament Fabrication (FFF) process and this waste can be converted into usable ecofriendly composites using ultrasonic joining technique. The joining study was done on the 3D printed supports of Poly Lactic Acid (PLA), Carbon fibre reinforced Poly Lactic Acid (CPLA), and Ceramic reinforced Poly Lactic Acid (CEPLA) samples. The samples are welded with 6 different combinations such as similar welding of PLA, CPLA and CEPLA, and dissimilar welding of CEPLA/CPLA, CEPLA/PLA, and CPLA/PLA. Similar and dissimilar ultrasonic welding was done with respect to varying the printing process parameters such as layer height, raster orientation and printing speed. The impact of various printing parameters on the joint possessions of the 3D printed supports was analysed in terms of the mechanical properties such as tensile strength and shore hardness value. The results show that, the maximum tensile strength was observed on the similar joints of Carbon fibre reinforced Poly Lactic Acid (CPLA) samples with layer height of 0.1 mm, printing speed of 20 mm/s and raster orientation of 90°. Fractured samples clearly shows that all the samples are failed under brittle mode of fracture and at lower printing speed the samples are evenly deposited, which results in proper bonding or fusion of the Joined raft support samples. This kind of refabrication method provides more benefit with lesser energy utilization compared to filament extrusion method for recycling of the 3D printed waste.
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