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Halogenated flame retardants raise environmental concerns and are considered harmful to human health. As a result, researchers have been searching for alternatives for many years. Fraunhofer researchers are focusing on sustainable phosphorus-based raw materials derived from corn steep liquor. The phytic acid it contains is an excellent natural flame retardant for biomaterials.

Using carbon dioxide as a feedstock, efficiently storing renewable energy, and making industrial processes less dependent on fossil fuels: Fraunhofer Institute for Applied Polymer Research IAP, Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT, and South Korean company SGC Energy plan to jointly advance technologies for energy conversion and energy storage. The collaboration will focus on CO₂ electrolysis, hydrogen technologies, fuel cells, and battery technologies. To this end, the partners have signed a Memorandum of Understanding.

Deep insights into complex mixtures of substances, more precise conclusions about structure-property relationships, and new possibilities for quality control and process optimization: With a new infrastructure for nuclear magnetic resonance spectroscopy (NMR), the Fraunhofer Institute for Applied Polymer Research IAP in Potsdam Science Park supports companies in the plastics, fiber, and materials industries in developing and improving advanced materials. The focus is on polymer materials—ranging from poorly soluble substances and gels to chemically resistant plastics and carbon fiber intermediates.

Self-actuating textile structures are used in a wide range of applications, such as medical technology, automation, architecture, agriculture, and the apparel industry. An example is the use of shading nets in greenhouses, which can be deployed and retracted depending on the sunlight intensity. The German Institutes of Textile and Fiber Research Denkendorf (DITF) are developing textiles based on shape-memory polymers with reversibly controllable geometry.

Developing the building blocks for sustainable chemistry using yeast—and reducing reliance on fossil-based feedstocks: Since March 2026, the Fraunhofer Institute for Applied Polymer Research IAP at Potsdam Science Park and the TAILOR junior research group at the University of Potsdam, funded by the German Federal Ministry of Research, Technology and Space (BMFTR), have joined forces to help make this vision a reality. Together, they offer companies seeking to make their processes more sustainable by using microorganisms an end-to-end development pipeline—from strain engineering and bioprocess optimization to industrial scale-up and application testing.

Bio-based polymers provide new possibilities for a circular plastics economy. Together with experts from industry and research, the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE will discuss the potential these polymers offer, the challenges that still need to be addressed, and will demonstrate their successful conversion into industrial applications in an interactive workshop on September 15, 2026, at the DECHEMA FORUM in Frankfurt.

For the industry, recycled materials are creating new opportunities in geotextile production. In the GREEN project, the Fraunhofer Cluster of Excel-lence Circular Plastics Economy CCPE demonstrates that recycled polypro-pylene (PP), polyethylene terephthalate (PET), and high-density polyeth-ylene (HDPE) can be processed into nonwovens, fibers, and membranes that meet industrial requirements. This creates opportunities for use in existing production lines and new value chains in the geotextile market.

Metallic effects on plastic surfaces have become standard in many industries, from automotive interiors and exteriors to toys and household appliances. However, injection-molded parts with metallic effects suffer from a well-known drawback: visible flow lines that appear as streaks and compromise the premium look. A new method for producing metallic effect pigments, currently being optimized at the Fraunhofer Institute for Applied Polymer Research IAP, enables high-quality metallic effects on plastic surfaces with significantly reduced flow-line visibility – without an additional coating step.

Microcapsules containing a reactive two-component adhesive can simplify bonding processes in industry and assembly while improving occupational safety: The adhesive is initially safely enclosed in capsules, contact with exposed reactive components can be reduced, and activation takes place only during pressing at room temperature. The Fraunhofer Institute for Applied Polymer Research IAP in Potsdam Science Park is looking for partners from industry and research who would like to contribute specific components, carrier materials or assembly processes for application-oriented testing.

How can materials automatically perform protective functions in the event of a fire, and why are sustainable flame retardants becoming increasingly important? The Fraunhofer Institute for Applied Polymer Research IAP will present answers to these questions at FeuerTrutz 2026 in Nuremberg. From June 24 to 25, 2026, researchers will showcase thermoresponsive functional materials and bio-based flame retardants for fire protection applications in construction, mobility, and industry in Hall 4.

A cost-effective and multifunctional filler for paints and coatings could be obtained from chicken feathers in the future: keratin. Researchers at two Fraunhofer Institutes have achieved promising results with this protein.

Since 2025, Fraunhofer IWU has been heading the Lightweight Design Research Field. This alliance brings together the expertise of 16 Fraunhofer institutes, creating a powerful, interdisciplinary platform along the entire lightweight engineering value chain—from material development to validated application in products. The goal is to provide companies with integrated research and development services “from a single source” and to transform innovations into industrial applications.

New findings from the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE show how commercial PBSA/PLA blends can be specifically tailored through industrial processing methods to make them suitable for flexible film applications. This opens up concrete bio-based alternatives to petro-chemical plastics.

A novel developed biomimetic tissue substitute combines precisely tunable mechanical properties with biological functionality and is now ready for applications in medical technology. The material was developed in the »PolyKARD« project by the Fraunhofer Institute for Applied Polymer Research IAP and the NMI Natural and Medical Sciences Institute. From April 20 to 24, 2026, the new material will be presented together with further developments from Fraunhofer IAP at the Hannover Messe, at the Fraunhofer joint booth in Hall 11, Stand D33.

A new extruded foam made from polybutylene succinate (PBS), developed by the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE, offers industrial companies a direct path to sustainable material solutions – without the need to invest in new equipment. This approach simultaneously addresses CO₂ reduction, compliance with regulatory requirements, and economic efficiency.

A new pilot plant in Guben is set to enable the production of bio-based carbon fibers. The plant is part of the Carbon Lab Factory Lausitz and will make an important contribution to the transformation of the Lausitz region—from a traditionally raw material- and basic industry-oriented region to a hub for innovative high-performance materials. The German federal government and the state of Brandenburg are providing the Fraunhofer Institute for Applied Polymer Research IAP with 53.3 million euros for this purpose.

Batteries must be powerful, safe, and sustainable — at the same time, they must be cost-effective to produce. At InterBattery 2026 in Seoul, Fraunhofer Institute for Applied Polymer Research IAP will present new materials for next-generation batteries. The focus will be on tailor-made polymer electrolytes, membranes and separators, bio-based carbon materials and high-performance catalysts — developed for industrial applications along the entire value chain.

Researchers at Fraunhofer have developed a new system that combines conventional product information, data for the digital product passport, and authenticity verification into a single counterfeit-proof QR code. This solution supports companies in complying with legal requirements while simultaneously enhancing product protection and traceability. The system can be easily integrated into existing printing lines. At this year’s Interpack—one of the world’s leading trade fairs for the packaging industry—the Fraunhofer consortium will showcase the ready-to-use technology for the first time.

Paper packaging offers a number of advantages over its plastic counterparts: It has a high recycling rate, lower CO₂ emissions, and lower disposal costs. However, it cannot yet be sealed without adhesives or layers of plastic—a disadvantage for manufacturing and recycling processes. In the PAPURE project, four Fraunhofer institutes are developing a laser-based process that enables completely adhesive-free paper packaging.

Polyurethanes (PUR) are found in many products, such as upholstered furniture, foam or insulation materials, flooring, paints and even medical catheter tubes. The production of these high-demand plastics, however, relies on toxic isocyanate. Fraunhofer researchers have now developed an alternative production process using harmless dicarbamate.

After two years of research and development, the German-Chilean project Power-to-MEDME-R&D was successfully completed. The focus was on sustainable production of green hydrogen as well as the derivatives methanol and dimethyl ether (DME) in Chile. Researchers at Fraunhofer Institute for Applied Polymer Research IAP in Germany developed iridium-reduced catalysts for hydrogen electrolysis. These reduce the cost of hydrogen production and are scalable through a unique process – a central foundation for industrial-scale hydrogen production and economic utilization.

Combining expertise and accelerating future-oriented developments – at the beginning of the year, the Fraunhofer Institute for Applied Polymer Research IAP in Potsdam Science Park is sharpening its institutional profile through structural and personnel changes, thereby strengthening its strategic orientation in line with growing research and industry requirements. The restructuring of the institute is reflected not only in personnel changes, but also in renaming and departmental changes.

Is it possible to recover plastic recyclates from previously unused waste streams in order to produce high-quality fibers and films? How can bio-based polymer fibers be manufactured so as to allow adjustable biodegradability? These are the questions being addressed by researchers from the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE in the Zirk-Tex project. As an alternative to mechanical processes, they are jointly developing innovative recycling methods for the production of sustainable roof underlayments and geosynthetics. This involves the analysis of the entire value chain at pilot scale.

Textile waste could serve as a valuable source of raw materials for sustainable plastics in the future, according to the joint TexPHB feasibility study conducted by the Fraunhofer Institute for Applied Polymer Research IAP, Beneficial Design Institute GmbH and matterr GmbH. The study will be presented to the public for the first time at a network meeting on 25 November 2025 at the State Chancellery in Potsdam.

Efficient use of methane and CO₂ from biogas: Thanks to novel flat membranes, biogas can be processed directly and energy-efficiently – even in small plants. In the Bio4Value project, the Fraunhofer Institute for Applied Polymer Research IAP in the Potsdam Science Park, together with KS Kunststoffbau GmbH and the Leibniz Institute for Agricultural Engineering and Bioeconomy ATB, is developing a technology that opens new perspectives for the material use of methane and CO₂.

Those who want to generate electricity for their own consumption using wind power need a powerful small wind turbine. Researchers at the Fraunhofer Institute for Applied Polymer Research IAP, in collaboration with the BBF Group, have developed a lightweight rotor that is specifically designed for operation in regions with low wind speeds. The first prototypes have now been delivered. These systems enable private households, businesses, or disaster relief organizations to set up a decentralized energy supply and use renewable energy efficiently.

How can the state of Brandenburg benefit from a circular textile industry? This question is addressed in the new policy paper "Closing the loop in the textile industry: Value creation in the state of Brandenburg." Based on the „TexPHB“ feasibility study funded by the Brandenburg Ministry of Climate Protection, it shows how textile waste can be integrated into new value chains.

How can new bio-based and biohybrid materials with improved features be developed faster? Six Fraunhofer institutes are jointly exploring this question in the SUBI²MA flagship project, using an innovative bio-based polyamide developed by Fraunhofer researchers as a model. Its specific properties make it a promising alternative to fossil-based plastics.

Stents are used to remove narrowings (stenosis) in blood vessels, stabilize the vessels and thus prevent heart attacks or strokes. However, the implantation process damages the inner wall of blood vessel, and in addition a foreign body material is inserted into the blood vessel wall. Both factors can contribute to restenosis of the affected vessel. Researchers at the Fraunhofer Institute for Applied Polymer Research IAP at Potsdam Science Park aim to address these issues with specially coated, biocompatible, degradable stents. The team won recognition for developing a prototype as part of the senetics Innovation Award 2025.

An innovative chemical process developed by the Fraunhofer Institute for Applied Polymer Research IAP enables the complete recycling of particleboards. In collaboration with the Eberswalde University for Sustainable Development HNEE, System 180 GmbH, and PreZero Holz GmbH, the institute has demonstrated that new wood components can be produced without the use of virgin material. The project was funded by the Agency for Renewable Resources FNR through the Federal Ministry of Food, Agriculture and Home Affairs BMLEH.