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The surge of single-use plastics consumption has generated vast volumes of polymer waste, threatening water supplies, marine wildlife, and quality of life in low-income communities. Mechanical recycling is suggested as the most sustainable method to reduce polymer pollution because it may extend the life cycle for these products. This study aims to use 3D printing technology as a means to process recycled High-Density Polyethylene (HDPE) to produce honeycomb sandwich core panels. These structures benefit from the lattice design as it can provide greater strength with a relatively low weight nature, and is commonly used in the automotive, aerospace, and the architecture industry. Honeycomb sandwich core panel’s wide range of applications may benefit from the transition from directly sourced polymers to a recycled alternative.To test the hypothesis that recycled HDPE may be used as an alternative material for the fabrication of honeycomb sandwich core panels, the material properties were analyzed through a tensile strength test, geometries were modeled, verified and optimized under Finite Element Analysis, recycled HDPE filament was obtained in the laboratory to produce panels via 3D printing.