I think about this a lot more than I’d like to admit...even if he did come back, what would be the reason? Luffy/Sanji et al. are leagues more powerful than they were back then, so unless he’s eaten a DF and mastered Haki, he won’t be a discernible threat in a fight; everything I just said applies to his captain as well, who he was still loyal to at their exit; I doubt he’d become an ally, so there’s seemingly little justification for that particular plot line to get resolved.
The only feasible way I could see this coming to pass is if Blackbeard somehow rounded up all of Luffy’s former vanquished foes (this would require a little research on his part but we know he’s capable of doing that), gave them all stolen DFs, and made them part of his fleet. Gin, Krieg, Kuro, even Arlong could all come back way more powerful and once again oppose the Straw Hats in the Final War. Not a scenario I really see as viable, but that’s about the only way any of them could return and have it make a little sense.