Researchers from the University of Maryland, Georgia Tech, and the University of Notre Dame have developed DissolvPCB, a 3D printing-based method for fabricating fully recyclable electronic circuits. Presented at UIST 2025, the technique combines polyvinyl alcohol (PVA) substrates with eutectic gallium–indium (EGaIn) liquid metal to produce circuit board assemblies (PCBAs) that can be dissolved in water, separating components for reuse and significantly cutting electronic waste.

Unlike conventional FR-4 PCBs, which require energy-intensive recycling, DissolvPCB allows PVA substrates to be re-extruded into filament and liquid metal to be reclaimed, enabling makerspaces and prototyping labs to recycle small-batch electronics locally.

The process uses FDM 3D printing with PVA filament to form substrates containing channels for liquid metal injection. A custom FreeCAD plugin automatically converts KiCad PCB designs into 3D-printable models with sockets for both through-hole and surface-mounted components. Demonstrations included circuits supporting up to 5A currents, 10 MHz signals, and even shape-changing devices such as a self-bending gripper powered by Joule heating.

In tests, the researchers achieved recovery rates of 99.4% for PVA and 98.6% for liquid metal. Lifecycle assessments showed that DissolvPCB outperformed CNC-milled FR-4 boards across eight environmental categories, including global warming potential and resource depletion.

“This work reimagines the material and manufacturing foundations of circuit boards, making sustainable recycling accessible using affordable tools and materials,” the team stated.

DissolvPCB builds on growing efforts in recyclable electronics, but stands out for its integration of low-cost hardware, automated software, and high material reuse. Future plans include improving repairability, automating metal injection, and expanding to 3D circuit routing.

As additive manufacturing grows, such advances highlight the potential of circular electronics. From biodegradable batteries to compostable conductive inks, research and industry are aligning toward reducing e-waste. DissolvPCB contributes to this shift by offering a practical, end-to-end recycling pathway for both PCB materials and components.