A method of manufacturing a composite product includes recovering a wet composite waste from at least one of the manufacturing process or an end-of-life product. The wet composite waste includes a first resin and a plurality of first fibers that are bound together with the first resin. The method also includes grinding the wet composite waste after recovering the wet composite waste. The method also includes mixing the wet composite waste with the second resin into a homogeneous mixture and placing the homogeneous mixture into a cavity. The method includes curing the second resin of the homogeneous mixture such that the homogenous mixture hardens to form a composite product that includes the first resin, the second resin, and the plurality of first fibers.

A method is provided for fabricating strong green parts using binder jetting in conjunction with a gaseous crosslinker. The process includes preparing a binder and a powder, printing the green part via selective binder deposition into powder layers, and exposing the green part to a gaseous crosslinker either during or after printing. The gaseous crosslinker chemically reacts with functional groups in the binder to form crosslinked networks, enhancing mechanical strength without requiring high-temperature sintering. In certain embodiments, polyethylenimine is used as the binder, Zeolite 13X as the powder, and carbon dioxide as the gaseous crosslinker, enabling the formation of chemically bonded green parts suitable for temperature-sensitive applications such as gas sorbents. The method enables full-part functionality, including tunable sorption properties and geometries, while expanding the range of materials compatible with binder jet fabrication.

A method is disclosed for binder jetting of strong green parts using a crosslinker to form covalent bonds among binder molecules. In the disclosed process, a powder and a binder are prepared, and a crosslinker is introduced either by premixing with the binder or powder, or by in-situ deposition through a printhead. During the printing process, the binder and crosslinker are selectively jetted into the powder bed to form green parts layer by layer. The green parts are subsequently cured to induce crosslinking and solvent removal, resulting in chemically bonded binder networks. This method enables the fabrication of mechanically robust green parts without requiring high-temperature sintering, thereby allowing use with heat-sensitive materials. The approach is applicable to a wide range of binders, powders, and crosslinkers, and is particularly suited for manufacturing sorbent structures for carbon capture, water treatment, and catalytic applications.