This study investigates the feasibility of direct pellet printing of polybutylene adipate-co-terephthalate (PBAT) for sustainable 3D printing. PBAT is a biodegradable polymer with favorable mechanical properties and compostability, making it suitable for environmentally friendly applications. The research aimed to print PBAT parts without converting pellets into filaments, which is a common limitation in conventional 3D printing. A custom printer was developed to feed PBAT pellets directly into the extruder, eliminating the need for filament production. The study evaluated the effects of nozzle temperature on the mechanical properties of printed PBAT. Tensile specimens were printed at varying nozzle temperatures (160°C, 180°C, and 200°C), and their mechanical properties and microstructure were analyzed. The results showed that increasing the nozzle temperature improved the mechanical properties of PBAT, with the highest performance achieved at 200°C, where the sample exhibited an elongation of 1379% and a tensile strength of 7.5 MPa. SEM images revealed that higher nozzle temperatures resulted in better print quality, with fewer microholes and improved layer adhesion. Additionally, the study examined the compressive strength and energy absorption properties of PBAT structures with different infill percentages (40% and 60%). The 60% infill density sample showed higher compressive strength (1338 KPa) and energy absorption compared to the 40% infill sample (1306 KPa). The results indicate that PBAT has potential for applications requiring impact resistance and energy absorption. The study also assessed the dimensional accuracy of 3D printed PBAT parts. The ability to maintain shape was evaluated by comparing printed parts with CAD models, and the expansion parameters were used to adjust the dimensions of the printed parts. The results showed that PBAT printed parts with 40% and 60% infill densities had good dimensional accuracy, comparable to conventional materials like PLA. The direct pellet printing method offers several advantages over conventional filament-based 3D printing. It eliminates the need for filament production, reduces material waste, and allows for the printing of a wide range of thermoplastic materials. This method is more cost-effective and environmentally friendly, making it a promising approach for sustainable 3D printing. The study demonstrates that PBAT can be successfully printed using direct pellet printing, highlighting its potential for various applications in sustainable manufacturing.This study investigates the feasibility of direct pellet printing of polybutylene adipate-co-terephthalate (PBAT) for sustainable 3D printing. PBAT is a biodegradable polymer with favorable mechanical properties and compostability, making it suitable for environmentally friendly applications. The research aimed to print PBAT parts without converting pellets into filaments, which is a common limitation in conventional 3D printing. A custom printer was developed to feed PBAT pellets directly into the extruder, eliminating the need for filament production. The study evaluated the effects of nozzle temperature on the mechanical properties of printed PBAT. Tensile specimens were printed at varying nozzle temperatures (160°C, 180°C, and 200°C), and their mechanical properties and microstructure were analyzed. The results showed that increasing the nozzle temperature improved the mechanical properties of PBAT, with the highest performance achieved at 200°C, where the sample exhibited an elongation of 1379% and a tensile strength of 7.5 MPa. SEM images revealed that higher nozzle temperatures resulted in better print quality, with fewer microholes and improved layer adhesion. Additionally, the study examined the compressive strength and energy absorption properties of PBAT structures with different infill percentages (40% and 60%). The 60% infill density sample showed higher compressive strength (1338 KPa) and energy absorption compared to the 40% infill sample (1306 KPa). The results indicate that PBAT has potential for applications requiring impact resistance and energy absorption. The study also assessed the dimensional accuracy of 3D printed PBAT parts. The ability to maintain shape was evaluated by comparing printed parts with CAD models, and the expansion parameters were used to adjust the dimensions of the printed parts. The results showed that PBAT printed parts with 40% and 60% infill densities had good dimensional accuracy, comparable to conventional materials like PLA. The direct pellet printing method offers several advantages over conventional filament-based 3D printing. It eliminates the need for filament production, reduces material waste, and allows for the printing of a wide range of thermoplastic materials. This method is more cost-effective and environmentally friendly, making it a promising approach for sustainable 3D printing. The study demonstrates that PBAT can be successfully printed using direct pellet printing, highlighting its potential for various applications in sustainable manufacturing.