Plastic is indispensable yet environmentally damaging, especially when recycling increases tool wear in manufacturing. This research develops optimized PVD hard coatings that protect production tools without hindering recyclability. By extending tool life and improving efficiency, it supports a more sustainable, circular plastic economy where materials can be reused with less waste.

This research advances metal additive manufacturing by replacing wasteful machining with laser-based powder fusion. Inspired by baking, printed metal parts are optimized through microstructural analysis. The approach produces complex geometries with equal or superior strength and durability while significantly reducing material waste, enabling cleaner, more sustainable manufacturing.