Plastics processing companies face the challenge of tapping into new sources of raw materials and closing material loops—all without compromising on quality, functionality, or cost-effectiveness. The use of alternative raw materials presents various challenges. Recycled materials can vary in composition and quality; bio-based and novel polymers often exhibit different processing behavior from established materials; and additives, fillers, or reinforcing fibers can alter a material’s structure and properties. As a result, new plastics generally cannot be used without modifications. It is crucial to consider the material, processing, and application as a unified whole. Fraunhofer IAP specifically tailors materials and processing methods to one another.

At Fakuma, various exhibits demonstrate what such solutions might look like. Depending on the industrial challenge, the key starting point may lie in polymer chemistry, formulation, processing, process parameters, or scale-up. This cross-material understanding helps companies identify the causes of unexpected material behavior and plan development paths more effectively.
 

How can the material properties of plastics be specifically enhanced?

One example is a flexible and recyclable film material based on polylactide (PLA). This is not a conventional compound. Instead, the PLA was specifically chemically modified. As a result, the originally rigid bioplastic gains an enhanced property profile for flexible film applications and can be processed on standard equipment in a manner similar to low-density polyethylene (LDPE).

Specific functionalities can also be integrated into plastics. Shape memory polymers expand the property profile to include programmable shape change: After being deformed, they can return to a previously defined shape through a temperature stimulus. The FOIM exhibit illustrates this effect: At 60 degrees Celsius, a 2.5-millimeter-thick polyurethane film expands into a 40-millimeter-high foam—an expansion by a factor of 16. Another demonstrator is a shrinkable door opener manufactured using 4D printing. It shows how temperature-activated shape changes can be combined with additive manufacturing to create functional components without sacrificing the possibility of mechanical recycling.
 

Design for Recycling: Incorporating Recycling Considerations Early in Material Development

In addition to new properties, recyclability is a key focus right from the material design stage. Because the matrix and reinforcing fibers are made of the same polymer, no labor-intensive separation steps between different material components are required during recycling. This is the case, for example, with the self-reinforced monomaterial Sc-PLA. This approach follows the “Design for Recycling” principle and combines bio-based raw materials with a material design optimized for recycling.
 

How Are Plastic and Textile Waste Transformed into New Raw Materials?

Taking it a step further is the use of plastic waste as a feedstock for new polymers. The recovery of terephthalic acid from polyethylene terephthalate (PET) is an example of circular carbon utilization. Fraunhofer IAP uses the recovered monomer to produce new polymers and investigates, among other things, their mechanical properties and color. PET is used, for example, in bottles, fibers, and films.

Even textile waste streams that are difficult to recycle can serve as a source of raw materials. Fraunhofer IAP is demonstrating an approach in which used textiles containing PET are used as a starting material for the production of the biopolymer polyhydroxybutyrate, or PHB for short. In this way, a waste stream is transformed into a raw material for new polymer materials.
 

How can the transition to bioplastics be achieved?

Together with industry partners, Fraunhofer IAP developed new grades of the bioplastic polybutylene succinate (PBS), produced them on a pilot scale, and processed them. These PBS grades are suitable for various processing methods, including injection molding, blow molding, thermoforming, extrusion, and spinning. Potential applications include packaging, consumer goods, and textiles.

It is clear that new types of plastics cannot be considered in isolation. The polymer structure and property profile must be suited to the respective processing method and the intended application. Polymer synthesis, material development, characterization, and processing are all interlinked.
 

How do bio-based carbon fibers support lightweight construction and energy technology?

This interplay is also crucial for bio-based carbon fibers. Carbon fibers combine low weight with high strength and stiffness. Fraunhofer IAP develops them from renewable raw materials such as cellulose or lignin and specifically tailors their properties—from mechanical characteristics, porosity, and geometry to electrical conductivity—by adjusting the starting material, fiber structure, and process parameters. Depending on their property profile, these bio-based carbon fibers are suitable for applications in lightweight construction as well as in batteries and fuel cells.

At Fakuma 2026, Fraunhofer IAP will provide insights into various approaches for a circular plastics industry—ranging from the use of alternative raw materials and materials designed for recycling to new polymer and fiber solutions. Through its membership in TecPart, the institute brings this expertise to the dialogue with manufacturers of technical plastic products and demonstrates how material development and industrial processing can be integrated.