A personalized orthopaedic device realised can be manufactured with Fused Filament Fabrication, exploiting dual material extrusion with recyclable TX1501 carbon-fiber-reinforced and TPU. The design of the splint is based on a custom parametric methodology that incorporates control of Voronoi pattern to achieve performance-driven material efficiency, while the printing parameters are determined after the implementation of custom toolpath printability tests. Finite Element Analysis (FEA), Physical Mechanical testing, Adhesion Testing and 3D Scanning procedures have been implemented to ensure and evaluate both the functionality and dimensional accuracy of the designed model, and the ease of material sorting for the subsequent recycling process. In addition, toxicological and antibacterial studies were carried out to the material in contact with the skin, to guarantee the safe use of the demonstrator. Furthermore, the developed reinforced TX1501 within Repair3D, has evaluated regarding its processability fluctuation through recycling cycles, by implementing customised interdependent parametrisation tests.