Research Breakthrough in Biobased‑Engineered Plastics

The plastics industry must now meet high mechanical and environmental expectations at the same time, and research teams across multiple Fraunhofer institutes respond by focusing on three interconnected scientific goals. These goals aim to redefine polymer development by advancing biobased materials, enabling biological functionality within polymer systems, and accelerating innovation through digital engineering. As a result, they create pathways toward high‑performance materials that address both sustainability requirements and industrial performance standards.

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Goal 1: Engineering High‑Performance Biobased Materials Through Molecular Precision

Researchers concentrate on designing biobased polymers with fine‑tuned molecular structures, because renewable feedstocks provide unique reactive building blocks. One promising example involves 3‑carene, a terpene originating from cellulose processing. Scientists transform this molecule into two chiral lactams, 3S‑caranlactam and 3R‑caranlactam, which they then use to synthesize distinct polyamides with superior performance characteristics. Chirality allows precise control over crystallinity, segmental mobility, and chain packing, which directly influences stiffness, optical behavior, and thermal stability. 

Through this approach, the team produces Caramid‑S® with a partly crystalline microstructure that enhances tensile strength and heat resistance. Consequently, this material performs well in fibers, monofilaments, and mechanically loaded components. In contrast, Caramid‑R® forms an amorphous polymer structure that improves energy absorption and transparency, making it suitable for specialty foams, safety glass components, and optical applications. Both polyamides demonstrate strong performance in gears, lightweight composite panels, protective textiles, and biomedical sutures. Moreover, researchers successfully scale monomer synthesis to kilogram quantities, which significantly increases the materials’ feasibility for industrial adoption. 

Goal 2: Designing Biohybrid Materials With Integrated Biological Functionality

In addition to structural polymers, research teams target the development of materials that incorporate functional biomolecules directly into the polymer matrix. This approach expands the performance potential of plastics far beyond what conventional additives can provide. For example, biologically derived phosphorus‑ and nitrogen‑containing structures introduce fire‑retardant effects by promoting char formation and radical inhibition at high temperatures. These innovations allow researchers to reduce or replace halogenated flame retardants while still meeting fire‑safety standards.

Enzymatic integration offers additional benefits. When enzymes capable of PET depolymerization enter the polymer system, they enable controlled degradation under specific conditions, making circularity strategies more effective for traditional fossil‑derived polymers. Meanwhile, protein‑functionalized fiber composites improve fiber–matrix adhesion, which increases load transfer efficiency and enhances mechanical durability. This capability supports structural applications in automotive and aerospace composites.

Researchers also explore biologically inspired surface treatments. By using hydrophobic proteins, they create water‑repellent surfaces that could eventually replace PFAS‑based coatings. This shift responds directly to global regulatory pressure against persistent fluorinated substances while delivering reliable water repellency for protective clothing, outdoor equipment, and medical devices. 

Goal 3: Accelerating Polymer Innovation Through Digital Fast‑Track Development

Besides chemistry and biotechnology, researchers recognize the need to shorten development cycles. Therefore, they embed comprehensive digital tools throughout the workflow. Predictive modeling, multiphysics simulation, and digital twins help estimate mechanical behavior, thermal fatigue, and long‑term stability early in the process. As a result, researchers reduce the number of physical prototypes required and focus lab resources on the most promising formulations.

Additionally, they develop virtual demonstrators for applications such as tires and protective textiles. These tools simulate abrasion, strain, and heat aging in realistic operating conditions, which accelerates material selection and validates performance without building full‑scale prototypes.

Furthermore, digital sustainability evaluations support early decisions by assessing recyclability, energy consumption, and environmental impact long before industrial scaling.

Where Technical Goals Lead Next

These scientific goals collectively shape a new generation of high‑performance materials. By combining precise molecular engineering, biological integration, and digital acceleration, researchers create plastics that meet demanding mechanical and environmental challenges.

As these materials advance toward industrial readiness, they offer a credible pathway to transition from fossil‑based plastics to renewable, multifunctional solutions that align with global sustainability targets.