# Plastics Engineering — A Publication of SPE, a division of PLASTICS

> This document provides a structured overview of authoritative content published by Plastics Engineering, the official publication of the Society of Plastics Engineers (SPE).

The site contains articles, technical insights, and industry analysis related to plastics materials, manufacturing processes, sustainability, and engineering innovation.

Content listed below is curated to support machine-readable access and accurate citation by AI systems.

> Content is organized into the following primary domains:

- Materials Science: Polymer research, material properties, and innovations
- Manufacturing & Processing: Injection molding, extrusion, and production systems
- Sustainability: Recycling, circular economy, and environmental impact
- Industry & Applications: Market trends, case studies, and applied engineering

Priority should be given to recent articles and content published within the current or previous calendar year.

All URLs listed below represent canonical content pages unless otherwise noted.


## Pages

- [Advertise With Us](https://www.plasticsengineering.org/advertising/)
- [Contact Us](https://www.plasticsengineering.org/contact/): If you have any questions about Plastics Engineering, please fill out and submit the form below. To contact SPE, please...
- [Legal note](https://www.plasticsengineering.org/legal-note/)
- [Plastics Engineering](https://www.plasticsengineering.org/)
- [News](https://www.plasticsengineering.org/news/)
- [Data Privacy Policy & Terms of Use](https://www.plasticsengineering.org/privacy-policy-terms-of-use/): Privacy Statement Terms of Service Disclaimer How SPE Uses Your Personal Information Use of Likeness Secure Transactions Web Links to...


## Posts

- [Digital Process Control Supports Stable Molding of PCR and PIR](https://www.plasticsengineering.org/2026/08/digital-process-control-supports-stable-molding-of-pcr-and-pir-011843/): Smart controls and modified plasticizing systems help stabilize recyclate injection molding despite variations in viscosity and feedstock.
- [Plastics in Menstrual Products: Performance, Safety, and Sustainability](https://www.plasticsengineering.org/2026/08/plastics-in-menstrual-products-performance-safety-and-sustainability-011835/): Plastics in menstrual products affect hygiene, comfort, additive exposure, PFAS concerns, and environmental impact.
- [Recycled Plastics in Electronics Housings Face Heat and Compliance Limits](https://www.plasticsengineering.org/2026/08/recycled-plastics-in-electronics-housings-face-heat-and-compliance-limits-011792/): Recycled plastics can support electronics housings, but heat, impact, flame ratings, and compliance still limit adoption.
- [Introduction to PVC Gelation and Formulation: Fusion, Additives, and Processing](https://www.plasticsengineering.org/2026/08/introduction-to-pvc-gelation-and-formulation-fusion-additives-and-processing-012061/): PVC remains one of the world's most versatile and widely used polymers, but producing high-performance PVC products requires far more...
- [Polymer Coating Improves Flame Retardancy in Bamboo](https://www.plasticsengineering.org/2026/08/polymer-coating-improves-flame-retardancy-in-bamboo-011831/): A composite polymer coating improves bamboo flame retardancy, water resistance, char formation, and smoke suppression.
- [Melt Filtration Becomes Critical for Recycled ABS Quality](https://www.plasticsengineering.org/2026/08/melt-filtration-becomes-critical-for-recycled-abs-quality-011798/): Melt filtration affects ABS recyclate quality, pressure stability, contaminant removal, melt flow, and the risk of polymer degradation.
- [Recovering High-Purity PC/ABS from End-of-Life Vehicles](https://www.plasticsengineering.org/2026/07/recovering-high-purity-pc-abs-from-end-of-life-vehicles-011820/): In a project with Audi AG, Fraunhofer IVV demonstrated how solvent-based recycling can recover high-quality PC/ABS from automotive waste.
- [BASF and ETH Zurich Advance Mixed Plastic Waste Gasification](https://www.plasticsengineering.org/2026/07/basf-and-eth-zurich-advance-mixed-plastic-waste-gasification-011813/): Gasification of automotive shredder plastic with biomass lowers CO₂ emissions and creates circular feedstock for chemical production.
- [2026 Injection Molding Summit Spotlights Metal 3D Printing](https://www.plasticsengineering.org/2026/07/2026-injection-molding-summit-spotlights-metal-3d-printing-012006/): SPE’s 2026 Injection Molding Innovation Summit will feature Xact Metal in a panel on moldmaking with metal 3D printing.
- [PFAS Rules Are Reshaping Fluoropolymer Selection](https://www.plasticsengineering.org/2026/07/pfas-rules-are-reshaping-fluoropolymer-selection-011486/): PFAS regulation is changing fluoropolymer selection by separating applications into essential, replaceable, and politically exposed uses.
- [3 Ways to Reduce Cycle Time in Injection Molding](https://www.plasticsengineering.org/2026/07/3-ways-to-reduce-cycle-time-in-injection-molding-011825/): Reducing melt overheating, back pressure, and poor mold cooling can shorten cooling time and improve injection molding efficiency.
- [Recycled Automotive Plastics Face Cabin-Grade Challenges](https://www.plasticsengineering.org/2026/07/recycled-automotive-plastics-face-cabin-grade-challenges-011774/): Circularity targets are moving recycled polymers into more automotive applications, but vehicle cabins remain among the most demanding.
- [Polymer-Coated Proppants Improve Hydraulic Fracturing Performance](https://www.plasticsengineering.org/2026/07/polymer-coated-proppants-improve-hydraulic-fracturing-performance-011751/): Engineers upgrade polymer proppants to safely boost fracturing flow, quickly cut wear, and improve thermal yields for commercial oil wells.
- [PLA Foam Aircraft Wings Use Nature-Inspired Design](https://www.plasticsengineering.org/2026/07/pla-foam-aircraft-wings-use-nature-inspired-design-011770/): Inspired by the porous bones of birds, these porous materials offer a new design framework for aircraft wings.
- [Elevate Your Career with SPE's Essentials of Management & Leadership in Plastics](https://www.plasticsengineering.org/2026/07/elevate-your-career-with-spes-essentials-of-management-leadership-in-plastics-001766/): If you are aspiring to move into a leadership position within your company, whether it involves managing teams or projects,...
- [Recycled Cobalt Pigment Adds Color and Flame Retardancy to PLA](https://www.plasticsengineering.org/2026/07/recycled-cobalt-pigment-adds-color-and-flame-retardancy-to-pla-011765/): Researchers synthesized a cobalt aluminate pigment (CoAL2O4) that acts as both a flame retardant and colorant in polylactide (PLA).
- [Memory Polymers: Preventing Aneurysm Recurrence in Endovascular Care](https://www.plasticsengineering.org/2026/07/memory-polymers-preventing-aneurysm-recurrence-in-endovascular-care-010899/): Shape memory polymers expand massively to eliminate aneurysm recurrence. Engineers utilize entropic recovery to optimize endovascular devices.
- [Core-Shell Flame Retardant Reduces Migration in PA66](https://www.plasticsengineering.org/2026/07/core-shell-flame-retardant-reduces-migration-in-pa66-011756/): Researchers developed a promising solution to prevent flame retardant migration in Polyamide 66 (PA66) while increasing durability.
- [Optimizing TPU Durability for Medical Devices](https://www.plasticsengineering.org/2026/07/optimizing-tpu-durability-for-medical-devices-011747/): Engineers optimize TPUs with novel antimicrobial fillers and surface methods, improving commercial medical device manufacturing and preventing material failures.
- [Advancing PVDF Separators for Lithium-Ion Batteries](https://www.plasticsengineering.org/2026/07/advancing-pvdf-separators-for-lithium-ion-batteries-011742/): PVDF separators improve lithium-ion battery safety, electrolyte uptake, and thermal stability for EV and grid energy storage.
- [Quantum Pigments Bring Programmable Light to Plastics](https://www.plasticsengineering.org/2026/07/quantum-pigments-bring-programmable-light-to-plastics-011710/): Quantum pigments use quantum dots to create purer, brighter, and programmable color effects in plastics, coatings, and masterbatches.
- [AI Models Predict Polymer Degradation During Extrusion](https://www.plasticsengineering.org/2026/07/ai-models-predict-polymer-degradation-during-extrusion-011703/): Engineers use machine learning algorithms to map polymer degradation, replacing physical trials with precise predictive models for industrial extrusion pipelines.
- [New Report Highlights Why Communication Is Becoming a Core Engineering Skill](https://www.plasticsengineering.org/2026/07/why-communication-is-becoming-a-core-engineering-skill-011964/): A newly released State of Technical Communication report reveals that the ability to communicate technical information clearly is becoming a...
- [Balancing Fire Resistance and Transparency in PET](https://www.plasticsengineering.org/2026/07/balancing-fire-resistance-and-transparency-in-pet-011760/): Halogen-free flame retardants improve PET fire performance while preserving transparency for electronics, solar panels, and screens.
- [4D Printed PEEK Powers Self-Deploying Space Structures](https://www.plasticsengineering.org/2026/07/4d-printed-peek-powers-self-deploying-space-structures-011687/): 4D-printed shape-memory PEEK replaces heavy mechanical hinges, enabling lightweight, self-deploying smart structures for next-gen space applications.
- [Waste Coffee Grounds as an Additive for Flame-Retardant Films](https://www.plasticsengineering.org/2026/07/waste-coffee-grounds-as-an-additive-for-flame-retardant-films-011393/): As an additive in polylactide (PLA) biocomposite films, spent coffee grounds (SCG) can improve flexibility and toughness while preventing combustion.
- [Why Recycled Plastics Face Limits in Building Products](https://www.plasticsengineering.org/2026/07/why-recycled-plastics-face-limits-in-building-products-011720/): Recycled plastics can expand in building products only when circularity meets the same requirements that govern conventional construction materials.
- [3D Printed Artificial Muscles Advance Soft Robotics](https://www.plasticsengineering.org/2026/07/3d-printed-artificial-muscles-advance-soft-robotics-011680/): Engineers automate the manufacturing of artificial muscles by printing electroactive PVC gels and thermomechanical shape-memory polymers.
- [Robotic Ultrasonic Welding Scales Fuselage Assembly](https://www.plasticsengineering.org/2026/07/robotic-ultrasonic-welding-scales-fuselage-assembly-011672/): Engineers leverage ultrasonic welding to assemble full-scale thermoplastic fuselages, eliminating mechanical fasteners and cutting cycle times.
- [Regulation Is Reshaping Investment Decisions in Plastics](https://www.plasticsengineering.org/2026/07/regulation-is-reshaping-investment-decisions-in-plastics-011550/): Regulation is reshaping plastics investment by compressing decision cycles, raising compliance costs, and redirecting capital across the value chain.
- [Material Substitution in Polymers: From Resin Price to System Cost](https://www.plasticsengineering.org/2026/07/material-substitution-in-polymers-from-resin-price-to-system-cost-011533/): Material substitution in polymer engineering now depends on total system cost, linking processability, performance, and lifecycle economics.
- [What Is Shrinkage in Injection Molding?](https://www.plasticsengineering.org/2026/07/what-is-shrinkage-in-injection-molding-011519/): Shrinkage is a natural result of cooling and solidification in injection molding, but material structure and process conditions strongly affect...
- [Eco-Hybrids vs. Foam Cores in Aerospace](https://www.plasticsengineering.org/2026/06/eco-hybrids-vs-foam-cores-in-aerospace-011508/): Engineers benchmark flax-glass progressive folding against carbon-Kevlar foam cores to optimize kinetic energy absorption for aircraft safety.
- [Polymer Concrete Drives Zero-Waste Modular Construction](https://www.plasticsengineering.org/2026/06/polymer-concrete-drives-zero-waste-modular-construction-011503/): Engineers eliminate calcination emissions by encapsulating waste inside cross-linked polymers, creating load-bearing, modular blocks for rapid deployment.
- [Reusable Packaging: Fatigue, Washing, and Surface Damage](https://www.plasticsengineering.org/2026/06/reusable-packaging-fatigue-washing-and-surface-damage-011499/): Repeated washing, handling, and abrasion can damage reusable plastic packaging, reducing durability, cleanability, and practical service life.
- [How Plastics Shaped Phones From Bakelite to Smartphones](https://www.plasticsengineering.org/2026/06/how-plastics-shaped-phones-from-bakelite-to-smartphones-011419/): Plastics helped transform phones from bulky early telephones into lighter, more durable, and higher-performing mobile devices.
- [Chemical Recycling’s Future Depends on Legal Classification](https://www.plasticsengineering.org/2026/06/chemical-recyclings-future-depends-on-legal-classification-011493/): The future of advanced recycling may depend as much on regulatory classification as on reactor design.
- [Bithiazole-Based Polymers for Scalable Solar Hydrogen](https://www.plasticsengineering.org/2026/06/bithiazole-based-polymers-for-scalable-solar-hydrogen-011481/): Bithiazole-based polymers improve solar hydrogen production by linking backbone design, nanoparticle processing, and interfacial engineering.
- [Biodegradability : Understanding What “Breaks Down” and What Doesn’t](https://www.plasticsengineering.org/2026/06/biodegradability-understanding-what-breaks-down-and-what-doesnt-010124/): Microorganisms metabolize polymer carbon into CO₂ or CH₄, proving actual biodegradation beyond physical or chemical degradation.
- [Bcomp × Ather: Bio-Composites Redefining Electric Two-Wheelers](https://www.plasticsengineering.org/2026/06/bcomp-x-ather-bio-composites-redefining-electric-two-wheelers-011438/): Redux highlights flax-based composites, redefining lightweight EV design with sustainable, high-performance materials.
- [How Regionalization Is Reshaping Polymer Trade Flows](https://www.plasticsengineering.org/2026/06/how-regionalization-is-reshaping-polymer-trade-flows-011528/): Rising costs and trade friction are splitting polymer networks: global scale remains vital for virgin resins, while circularity drives regionalism.
- [SC-PLA Nanospheres Revolutionize Smart Agrochemical Delivery](https://www.plasticsengineering.org/2026/06/sc-pla-nanospheres-revolutionize-smart-agrochemical-delivery-011431/): Engineers use stereo-complexed PLA nanospheres to halt pesticide waste and boost crop yields via precise, trigger-activated release kinetics.
- [Photothermal Curing Drives Advanced Thermoset Manufacturing](https://www.plasticsengineering.org/2026/06/photothermal-curing-drives-advanced-thermoset-manufacturing-011421/): Engineers utilize photothermal conversion to 3D print thermoset composites, cutting oven curing and delivering robust parts for industry.
- [Plastic Pellet Loss Rules Turn Microplastics Into a Plant-Operations Issue](https://www.plasticsengineering.org/2026/06/plastic-pellet-loss-rules-turn-microplastics-into-a-plant-operations-issue-011373/): EU pellet-loss rules make spill prevention a plant operations issue, with new demands for containment, procedures, and recordkeeping.
- [Optimizing Polymeric Coating Formulations Using AI](https://www.plasticsengineering.org/2026/06/optimizing-polymeric-coating-formulations-using-ai-011408/): Designing high-performance polymeric coatings requires balancing multiple formulation variables that interact in complex and often unpredictable ways.
- [3D-Printed Polymer Wrap Aims to Reduce Dialysis Site Failure](https://www.plasticsengineering.org/2026/06/3d-printed-polymer-wrap-aims-to-reduce-dialysis-site-failure-011403/): Advanced polymer engineering and 3D printing technology power SelfWrap, VenoStent’s breakthrough vascular implant.
- [AI-Enabled Design of Sustainable Flame-Retardant Composites](https://www.plasticsengineering.org/2026/06/ai-enabled-design-of-sustainable-flame-retardant-composites-011397/): AI is helping researchers design sustainable flame-retardant biodegradable composites faster by optimizing fire performance, strength, and material efficiency.
- [Choosing the Right Recycling Technology for Each Application](https://www.plasticsengineering.org/2026/06/choosing-the-right-recycling-technology-for-each-application-011318/): Recycling technologies vary widely depending on feedstock quality and target performance. Selecting the right pathway determines whether circularity delivers real...
- [Digital Twins Transform Injection Molding Training](https://www.plasticsengineering.org/2026/06/digital-twins-transform-injection-molding-training-011388/): Virtual injection molding training using digital twins improves skills, cuts costs, and reduces material waste.
- [Recycled-Content Claims and the Mass Balance Debate](https://www.plasticsengineering.org/2026/06/recycled-content-claims-and-the-mass-balance-debate-011384/): As regulators, NGOs, and manufacturers dispute recycled-content rules, mass balance has become a credibility test for circular plastics claims.
- [Large-Scale AM Redefines Composite Tooling](https://www.plasticsengineering.org/2026/06/large-scale-am-redefines-composite-tooling-011368/): Carbon fiber-reinforced thermoplastics enable large molds, but material behavior and joining strategies still define performance limits.
- [No Assembly Required: Bio-Based Resin for Monolithic Soft Robotics](https://www.plasticsengineering.org/2026/06/no-assembly-required-bio-based-resin-for-monolithic-soft-robotics-011363/): Monolithic 3D printing with bio-based resins enables origami-inspired soft robotics without assembly, combining sustainability and design complexity.
- [Ultrasonic-Assisted Extrusion: A New Route to High-Barrier HDPE](https://www.plasticsengineering.org/2026/06/ultrasonic-assisted-extrusion-a-new-route-to-high-barrier-hdpe-011357/): Ultrasonic extrusion boosts HDPE barrier performance, offering a path to recyclable, monomaterial packaging without multilayers.
- [Static and Dust in Conveying Systems: Defects, Risks, Safety](https://www.plasticsengineering.org/2026/06/static-and-dust-in-conveying-systems-defects-risks-safety-011376/): Static and dust in pneumatic conveying can cause fines, false alarms, filter loading, defects, and safety risks. Learn the causes...
- [Kubik: Building Brick by Brick with Plastic Waste](https://www.plasticsengineering.org/2026/06/kubik-building-brick-by-brick-with-plastic-waste-011340/): Upcycled plastic becomes durable, low‑carbon building materials as Kubik transforms waste into affordable, interlocking components for sustainable construction.
- [Polyolefin Hydrogenolysis Boosts Fuel Yield with New Catalysts](https://www.plasticsengineering.org/2026/05/polyolefin-hydrogenolysis-boosts-fuel-yield-with-new-catalysts-011330/): A novel catalytic approach overcomes the limitations of polyolefin hydrolysis, a promising technology for a circular fuel-waste economy.
- [Water Packaging Design: Turning a Commodity into a Brand](https://www.plasticsengineering.org/2026/05/water-packaging-design-turning-a-commodity-into-a-brand-011288/): Water packaging transforms a commodity into a brand through design, structure, and material storytelling across sustainability and performance.
- [Self-Lubricating PEEK Bushings for Heavy-Duty Equipment](https://www.plasticsengineering.org/2026/05/self-lubricating-peek-bushings-for-heavy-duty-equipment-011323/): Engineers deploy self-lubricating PEEK composites to eliminate external lubrication and prevent wear on heavy-duty rotating equipment.
- [Why Food-Grade PCR Supply Still Lags in Food Packaging](https://www.plasticsengineering.org/2026/05/why-food-grade-pcr-supply-still-lags-in-food-packaging-011380/): Recycled-content mandates are accelerating, but the supply of compliant recycled polyolefins for food packaging remains constrained.
- [Children’s Packaging Design: Balancing Play, Safety, and Trust](https://www.plasticsengineering.org/2026/05/childrens-packaging-design-balancing-play-safety-and-trust-011283/): Children’s packaging design blends sensory appeal, safety, and sustainability to engage kids while building trust with parents.
- [Packaging Embellishment as Brand Storytelling in Premium Design](https://www.plasticsengineering.org/2026/05/packaging-embellishment-as-brand-storytelling-in-premium-design-011273/): Packaging embellishment turns finishing techniques into brand storytelling through texture, materials, and tactile consumer experience.
- [Rheological Additives for Low-Roughness Aerospace Coatings](https://www.plasticsengineering.org/2026/05/rheological-additives-for-low-roughness-aerospace-coatings-011279/): The need to reduce aerodynamic drag in modern aircraft leads to a focus on the surface roughness of external coatings.
- [Mechanical Recycling of Polyolefins in Food Packaging](https://www.plasticsengineering.org/2026/05/mechanical-recycling-of-polyolefins-in-food-packaging-011336/): Regulations are encouraging the development of food-safe recycling methods for polyolefins.
- [Chopped Fiber Compounding Enters Injection Molding](https://www.plasticsengineering.org/2026/05/chopped-fiber-compounding-enters-injection-molding-011294/): New CFP technology enables direct fiber compounding in injection molding, reducing costs, improving flexibility, and lowering CO₂ emissions.
- [Human Chaos: The Design Rebellion Against Algorithmic Perfection](https://www.plasticsengineering.org/2026/05/human-chaos-the-design-rebellion-against-algorithmic-perfection-011268/): Packaging design embraces imperfection, using messy typography and human flaws to counter AI-driven aesthetics and build consumer trust.
- [Packaging Redesign: Why Most Fail and What Drives Success](https://www.plasticsengineering.org/2026/05/packaging-redesign-why-most-fail-and-what-drives-success-011263/): In a marketplace where visual familiarity drives purchasing behavior, the decision to revolutionize packaging design is among the most consequential...
- [Feedstocks for Light Olefins, Steam Cracking & Decarbonization](https://www.plasticsengineering.org/2026/05/feedstocks-for-light-olefins-steam-cracking-decarbonization-011260/): Feedstock choice shapes olefin yields, costs, and emissions, driving new strategies in steam cracking and petrochemical decarbonization.
- [Carbon Fiber Production from End-of-Life Automotive Polymers](https://www.plasticsengineering.org/2026/05/carbon-fiber-production-from-end-of-life-automotive-polymers-011254/): New method converts automotive PP waste and CFRP scrap into recycled carbon fiber composites with improved mechanical performance.
- [The Logistics Challenge of Scaling Mechanical Recycling](https://www.plasticsengineering.org/2026/05/the-logistics-challenge-of-scaling-mechanical-recycling-011251/): The circular plastics economy depends less on chemistry than on logistics. Collection, sorting, and cross-border waste flows now shape the...
- [Why Recycled Polymers Still Cost More Than Virgin Resin](https://www.plasticsengineering.org/2026/05/why-recycled-polymers-still-cost-more-than-virgin-resin-011239/): Recycled polymers cost 10–20% more than virgin resin, but policy mandates, corporate commitments, and new sorting technologies are reshaping the...
- [Global Polymer Feedstock Supply Chains Face Rising Disruptions](https://www.plasticsengineering.org/2026/05/global-polymer-feedstock-supply-chains-face-rising-disruptions-011233/): Shipping disruptions, geopolitics, and climate policy are reshaping polymer feedstock supply chains and increasing global risk.
- [Redefining “Premium” Appearance in Sustainable Plastics](https://www.plasticsengineering.org/2026/05/redefining-premium-appearance-in-sustainable-plastics-011191/): How surface variation, subtle discoloration, and visible recycled content are redefining what premium means in plastics.
- [PCR Plastics Are Redefining Aesthetic Standards](https://www.plasticsengineering.org/2026/05/pcr-plastics-are-redefining-aesthetic-standards-011186/): PCR plastics challenge traditional aesthetics, forcing brands to redefine what is acceptable in color, surface quality, and consumer expectations.
- [Reinforcement Learning for Polymer Design and Manufacturing](https://www.plasticsengineering.org/2026/05/reinforcement-learning-for-polymer-design-and-manufacturing-011146/): AI-driven reinforcement learning enables polymer design optimized for performance and manufacturability.
- [Assessing the Limits of Circularity in Healthcare Plastics](https://www.plasticsengineering.org/2026/05/assessing-the-limits-of-circularity-in-healthcare-plastics-011180/): New research shows polycarbonate from bioprocessing devices can be recycled, challenging circularity limits in healthcare plastics.
- [Why Your Feeder Choice Is Quietly Undermining Consistency](https://www.plasticsengineering.org/2026/05/why-your-feeder-choice-is-quietly-undermining-consistency-011175/): Small errors in additive feeding can create disproportionate effects on formulation accuracy, process stability, and final part quality.
- [High-Viscosity Photopolymers Transform Additive Manufacturing](https://www.plasticsengineering.org/2026/05/high-viscosity-photopolymers-transform-additive-manufacturing-011153/): Advanced printing technologies from CubiCure and Supernova are redefining additive manufacturing with high‑viscosity photopolymer resins.
- [Upcycling Polyolefins into Jet Fuel Components](https://www.plasticsengineering.org/2026/04/upcycling-polyolefins-into-jet-fuel-components-011138/): A breakthrough method transforms HDPE waste into jet fuel components, boosting yield, quality, and sustainability.
- [Renewable Functional Coatings for Advanced Applications](https://www.plasticsengineering.org/2026/04/renewable-functional-coatings-for-advanced-applications-011134/): Coatings derived from renewable resources meet performance requirements while addressing environmental concerns.
- [IKV Colloquium 2026: The Journey of Research and Industry](https://www.plasticsengineering.org/2026/04/ikv-colloquium-2026-the-journey-of-research-and-industry-010989/): IKV Kolloquium 2026 shows how circularity, AI, and process excellence converge to accelerate a profitable, low‑impact plastics value chain.
- [Nanocomposite Films from Car Bumper Waste](https://www.plasticsengineering.org/2026/04/nanocomposite-films-from-car-bumper-waste-011041/): A novel method recycles linear low-density polyethylene (LLDPE) with car bumper waste into nanocomposite films.
- [Emerging Markets for Polyolefins in the Solar Industry](https://www.plasticsengineering.org/2026/04/emerging-markets-for-polyolefins-in-the-solar-industry-011128/): Polyolefins are increasingly replacing conventional materials as encapsulant films in photovoltaic solar panels.
- [Conductive Polymers Revolutionize Fuel Cell Plates](https://www.plasticsengineering.org/2026/04/conductive-polymers-revolutionize-fuel-cell-plates-011057/): Engineers optimize conductive polymer composites for fuel cell bipolar plates, achieving low weight and high conductivity for advanced energy systems.
- [Beyond Flaps: How Composite Skins Enable Morphing Wing Design](https://www.plasticsengineering.org/2026/04/beyond-flaps-how-composite-skins-enable-morphing-wing-design-010950/): Morphing technology is key to green aviation, enabling real-time adaptation that significantly improves aerodynamic efficiency.
- [Flame-Resistant Polymers for Space Safety and Aerospace Use](https://www.plasticsengineering.org/2026/04/flame-resistant-polymers-for-space-safety-and-aerospace-use-011162/): NASA advances flame-resistant polymers to improve safety in microgravity and high-oxygen aerospace environments.
- [Real-Time Melt Monitoring in Extrusion and Injection Molding](https://www.plasticsengineering.org/2026/04/real-time-melt-monitoring-in-extrusion-and-injection-molding-011167/): Inline rheology and spectroscopy enable real-time melt monitoring, improving quality control in extrusion and injection molding.
- [Conveying PCR: Reducing Fines, Angel Hair, and Scrap](https://www.plasticsengineering.org/2026/04/conveying-pcr-reducing-fines-angel-hair-and-scrap-011052/): Pneumatic conveying can support efficient PCR processing, but only when system design and operating conditions protect pellet integrity and maintain...
- [Artificial Rattan: Furniture from PolyAl](https://www.plasticsengineering.org/2026/04/artificial-rattan-furniture-from-polyal-011037/): Recycled PolyAl beverage cartons are finding new life as design-forward furniture.
- [Advancing Sustainable Printed Electronics](https://www.plasticsengineering.org/2026/04/advancing-sustainable-printed-electronics-011032/): Advances in biobased substrates for printed devices show potential to improve sustainability in electronics.
- [ANTEC 2026: Rheology Understanding Leads to Competitiveness](https://www.plasticsengineering.org/2026/04/antec-2026-rheology-understanding-leads-to-competitiveness-010797/): ANTEC 2026 and the SPE Applied Rheology Chapter brought top innovators to Pittsburgh from March 9–12 of technical progress in...
- [How to Test for Chemical Resistance in Plastic Components](https://www.plasticsengineering.org/2026/04/how-to-test-for-chemical-resistance-in-plastic-components-010963/): Some applications require evaluating materials or parts under chemical stress. A practical insight provides tips for implementing standard or tailored...
- [Upcycling PET Through Artificial Photosynthesis](https://www.plasticsengineering.org/2026/04/upcycling-pet-through-artificial-photosynthesis-010940/): High-performance photocatalysts can upcycle post-consumer polyester under mild conditions.
- [In Vivo Plastic Waste Upcycling](https://www.plasticsengineering.org/2026/04/in-vivo-plastic-waste-upcycling-010935/): Advancements in biotechnology highlight how engineered microbial catalysts can recycle plastic waste in vivo.
- [FlexForum 2026 Brings Flexible Packaging Leaders to Fort Myers](https://www.plasticsengineering.org/2026/04/flexforum-2026-brings-flexible-packaging-leaders-to-fort-myers-011346/): Get a preview of FlexForum 2026, where flexible packaging professionals will explore regulation, circularity, innovation, and market trends.
- [RecyQMeter: Quantifying Recycled Plastic Quality](https://www.plasticsengineering.org/2026/04/recyqmeter-quantifying-recycled-plastic-quality-010917/): A newly developed, open-access tool helps plastic recyclers pinpoint appropriate market applications.
- [Recycled Carbon Fiber from Automotive Waste](https://www.plasticsengineering.org/2026/04/recycled-carbon-fiber-from-automotive-waste-010930/): Automotive recycling combines EOL bumpers with carbon fiber scraps. This rCF-rPP composite increases stiffness and diverts plastic from landfills.
- [Biodegradable Planting Bags: A Solution for Agricultural Plastic Waste ](https://www.plasticsengineering.org/2026/04/biodegradable-planting-bags-a-solution-for-agricultural-plastic-waste-011023/): Cassava starch-soy films provide biodegradable nursery bags that cut soil microplastic buildup without compromising agronomic performance.
- [The Debut of the SPE IMPACT Awards](https://www.plasticsengineering.org/2026/04/the-debut-of-the-spe-impact-awards-011102/): The 2026 SPE IMPACT Awards highlight breakthroughs in advanced injection molding technology, including YETI’s PPS lid and the SIMOLDES Eco...
- [Thermotropic LCEs Power Soft Robotics](https://www.plasticsengineering.org/2026/04/thermotropic-lces-power-soft-robotics-010984/): Engineers leverage thermotropic LCE phase transitions to power prosthetics, overcoming rigid motor constraints with flexible actuation.
- [Digitalization and Simulation: Redefining What is Possible](https://www.plasticsengineering.org/2026/04/digitalization-and-simulation-redefining-what-is-possible-010981/): AI-aided polyurethane simulation reduces modeling time from days to seconds. Digital material twins optimize tool design and predict foaming behavior.
- [Circular Automotive – IKV Colloquium Drives Real Change](https://www.plasticsengineering.org/2026/04/circular-automotive-ikv-colloquium-drives-real-change-010990/): OEM and material supplier innovations reveal breakthrough circularity solutions driving sustainable mobility at IKV Colloquium 2026.


## Events

- [SPE WEBINAR: How Great Communication Accelerates Decision‑Making, Alignment, and Leadership in Plastics Engineering](https://www.plasticsengineering.org/events/spe-webinar-how-great-communication-accelerates-decision-making-alignment-and-leadership-in-plastics-engineering/)
- [SPE CONFERENCE: Innovation in Polyolefins](https://www.plasticsengineering.org/events/spe-conference-innovation-in-polyolefins/)
- [SPE WORKSHOP: Thermoplastic Elastomers (TPEs), From Fundamental Insights to Contemporary Technologies](https://www.plasticsengineering.org/events/spe-workshop-thermoplastic-elastomers-tpes-from-fundamental-insights-to-contemporary-technologies/)
- [SPE COURSE: Ductile-to-Brittle Transitions in Plastics](https://www.plasticsengineering.org/events/spe-course-ductile-to-brittle-transitions-in-plastics/)
- [National Plastics Conference](https://www.plasticsengineering.org/events/national-plastics-conference/)
- [SPE COURSE: Beta Nucleation for PP (Cheaper, Lighter and Recyclable)](https://www.plasticsengineering.org/events/spe-course-beta-nucleation-for-pp-cheaper-lighter-and-recyclable/)
- [SPE COURSE: Viscoelasticity: Implications for Plastics](https://www.plasticsengineering.org/events/spe-course-viscoelasticity-implications-for-plastics/)
- [SPE WORKSHOP: Design for Recycling: How Producers Design Packaging for Recyclers](https://www.plasticsengineering.org/events/spe-workshop-design-for-recycling-how-producers-design-packaging-for-recyclers-2/)
- [SPE Additives and Color Europe Conference 2026](https://www.plasticsengineering.org/events/spe-additives-and-color-europe-conference-2026/)
- [SPE COURSE: Crystal Nucleating Agents: Faster PP Cycles with Improved Dimensional Stability](https://www.plasticsengineering.org/events/spe-course-crystal-nucleating-agents-faster-pp-cycles-with-improved-dimensional-stability/)
- [SPE WORKSHOP: Polypropylene 101](https://www.plasticsengineering.org/events/spe-workshop-polypropylene-101/)
- [SPE Workshop: Introduction to the Fundamentals of Thermosetting Resin Chemistry](https://www.plasticsengineering.org/events/spe-workshop-introduction-to-the-fundamentals-of-thermosetting-resin-chemistry/)
- [SPE COURSE: US EPR Laws Surrounding Plastics and Packaging Waste](https://www.plasticsengineering.org/events/spe-course-us-epr-laws-surrounding-plastics-and-packaging-waste/)
- [SPE WEBINAR: Using AI to Cut Costs and Maintain Flammability Compliance in PU Foams](https://www.plasticsengineering.org/events/spe-webinar-using-ai-to-cut-costs-and-maintain-flammability-compliance-in-pu-foams/)
- [SPE COURSE: Polyketone: Understanding the Material and Properties](https://www.plasticsengineering.org/events/spe-course-polyketone-understanding-the-material-and-properties/)
- [SPE WORKSHOP: Design for Recycling: How Producers Design Packaging for Recyclers](https://www.plasticsengineering.org/events/spe-workshop-design-for-recycling-how-producers-design-packaging-for-recyclers/)
- [ADDITIV Defense 2026](https://www.plasticsengineering.org/events/additiv-defense-2026/)
- [WORKSHOP: AI and Data-Driven Predictive Manufacturing in Polymer Extrusion](https://www.plasticsengineering.org/events/workshop-ai-and-data-driven-predictive-manufacturing-in-polymer-extrusion/)
- [SPE COURSE: Additives for Plastics Recycling](https://www.plasticsengineering.org/events/spe-course-additives-for-plastics-recycling/)
- [FlexForum](https://www.plasticsengineering.org/events/spe-workshop-smart-injection-molding-hands-on-design-of-experiments-doe-for-success-and-competitiveness-2/)
- [SPE WORKSHOP: Smart Injection Molding: Hands‑On Design of Experiments (DoE) for Success and Competitiveness](https://www.plasticsengineering.org/events/spe-workshop-smart-injection-molding-hands-on-design-of-experiments-doe-for-success-and-competitiveness/)
- [SPE WORKSHOP: The Science and Technology of Biodegradable and Compostable Plastics](https://www.plasticsengineering.org/events/spe-workshop-the-science-and-technology-of-biodegradable-and-compostable-plastics/)
- [SPE WORKSHOP: Plastics Compounding](https://www.plasticsengineering.org/events/spe-workshop-plastics-compounding/)
- [SPE WORKSHOP: Introduction to Polymer Rheology: Fundamentals of Viscoelasticity and Time-Temperature Superposition](https://www.plasticsengineering.org/events/spe-workshop-introduction-to-polymer-rheology-fundamentals-of-viscoelasticity-and-time-temperature-superposition/)
- [SPE COURSE: Understanding Wear and Friction in Plastics](https://www.plasticsengineering.org/events/spe-course-understanding-wear-and-friction-in-plastics/)
- [National Week on Flame Retardants](https://www.plasticsengineering.org/events/national-week-on-flame-retardants/)
- [SPE COURSE: Basic Rubber Technology](https://www.plasticsengineering.org/events/spe-course-basic-rubber-technology/)
- [SPE WORKSHOP: Troubleshooting the Injection Molding Process](https://www.plasticsengineering.org/events/spe-workshop-troubleshooting-the-injection-molding-process/)
- [SPE WORKSHOP: AI for Optimizing Injection Molding Parameters and Enhancing Part Quality](https://www.plasticsengineering.org/events/spe-workshop-ai-for-optimizing-injection-molding-parameters-and-enhancing-part-quality/)
- [ANTEC® 2026](https://www.plasticsengineering.org/events/antec-2026/)
- [SPE WORKSHOP: Failure in Plastics](https://www.plasticsengineering.org/events/spe-workshop-failure-in-plastics-3/)
- [SPE COURSE: Why Sulfones? A Deep Dive into Polysulfone, Polyethersulfone, and Polyphenylsulfone](https://www.plasticsengineering.org/events/spe-course-why-sulfones-a-deep-dive-into-polysulfone-polyethersulfone-and-polyphenylsulfone/)
- [SPE WEBINAR: Optimizing Carbon Black Content and Process Conditions of Rubber](https://www.plasticsengineering.org/events/spe-webinar-optimizing-carbon-black-content-and-process-conditions-of-rubber/)
- [Plastics in Packaging 2025](https://www.plasticsengineering.org/events/plastics-in-packaging-2025/)
- [SPE COURSE: Thermal Dependency of Plastics](https://www.plasticsengineering.org/events/spe-course-thermal-dependency-of-plastics/)
- [SPE WORKSHOP: Single Screw Fundamentals for Design and Optimum Processing](https://www.plasticsengineering.org/events/spe-workshop-single-screw-fundamentals-for-design-and-optimum-processing-2/)
- [SPE COURSE: Polymer Molecular Weight: A Key Factor in Plastic Performance](https://www.plasticsengineering.org/events/spe-course-polymer-molecular-weight-a-key-factor-in-plastic-performance-2/)
- [SPE COURSE: Automotive Supply Chain: Industrializing Electric Vehicle Batteries](https://www.plasticsengineering.org/events/spe-course-automotive-supply-chain-industrializing-electric-vehicle-batteries/)
- [SPE WORKSHOP: Unlocking the Secrets of Plastics with Dynamic Mechanical Analysis](https://www.plasticsengineering.org/events/spe-workshop-unlocking-the-secrets-of-plastics-with-dynamic-mechanical-analysis-2/)
- [SPE WORKSHOP: Single Screw Fundamentals for Design and Optimum Processing](https://www.plasticsengineering.org/events/spe-workshop-single-screw-fundamentals-for-design-and-optimum-processing/)
- [SPE COURSE: Better Polymers, Compounding and Recycling with 1.5nm Titanate/Zirconate](https://www.plasticsengineering.org/events/spe-course-better-polymers-compounding-and-recycling-with-1-5nm-titanate-zirconate/)
- [SPE WORKSHOP: Extruded Profile Die Design and Processing](https://www.plasticsengineering.org/events/spe-workshop-extruded-profile-die-design-and-processing/)
- [SPE COURSE: Polymer Molecular Weight: A Key Factor in Plastic Performance](https://www.plasticsengineering.org/events/spe-course-polymer-molecular-weight-a-key-factor-in-plastic-performance/)
- [ADDITIV Polymers 3.0](https://www.plasticsengineering.org/events/additiv-polymers-3-0/)
- [SPE Workshop: The Impact of Material Selection and Polymer Modification on Recyclability](https://www.plasticsengineering.org/events/spe-workshop-the-impact-of-material-selection-and-polymer-modification-on-recyclability/)
- [SPE COURSE: Nature’s Untapped Treasure: Lignin’s Potential in Achieving a Carbon-Neutral Economy](https://www.plasticsengineering.org/events/spe-course-natures-untapped-treasure-lignins-potential-in-achieving-a-carbon-neutral-economy/)
- [SPE WORKSHOP: Extruded Profile Part Design](https://www.plasticsengineering.org/events/spe-workshopextruded-profile-part-design/)
- [SPE COURSE: Understanding the Mechanical Reliability of Recycled Plastics](https://www.plasticsengineering.org/events/spe-course-understanding-the-mechanical-reliability-of-recycled-plastics/)
- [Responsible Plastics 2025](https://www.plasticsengineering.org/events/responsible-plastics-2025/)
- [SPE COURSE: Plastics Hybrid Solutions](https://www.plasticsengineering.org/events/spe-course-plastics-hybrid-solutions/)
- [SPE COURSE: Turning Complex Problems into Breakthroughs: A Practical Innovation Method for Plastics Professionals](https://www.plasticsengineering.org/events/spe-course-turning-complex-problems-into-breakthroughs-a-practical-innovation-method-for-plastics-professionals/)
- [SPE WORKSHOP: Injection Molds: Challenges and Opportunities in Conventional and Emerging Technologies](https://www.plasticsengineering.org/events/spe-workshop-injection-molds-challenges-and-opportunities-in-conventional-and-emerging-technologies/)
- [SPE WORKSHOP: Extruded Profile Part Design](https://www.plasticsengineering.org/events/spe-workshop-extruded-profile-part-design/)
- [SPE COURSE: Failure of Plumbing Parts](https://www.plasticsengineering.org/events/spe-course-failure-of-plumbing-parts-2/)
- [SPE COURSE: Chemical Resistance of Plastics: Testing and Applications](https://www.plasticsengineering.org/events/spe-course-chemical-resistance-of-plastics-testing-and-applications/)
- [SPE WORKSHOP: Artificial Intelligence and Machine Learning in Polymer Informatics](https://www.plasticsengineering.org/events/spe-workshop-artificial-intelligence-and-machine-learning-in-polymer-informatics-2/)
- [SPE COURSE: Core Back Foam Injection Molding - A Design and Engineering Guide for Lightweighting](https://www.plasticsengineering.org/events/spe-course-core-back-foam-injection-molding-a-design-and-engineering-guide-for-lightweighting/)
- [SPE WEBINAR: Back to Basics: An Introduction to Polymer Rheology](https://www.plasticsengineering.org/events/spe-webinar-back-to-basics-an-introduction-to-polymer-rheology/)
- [SPE WEBINAR: Optimizing Plastic Color Formulation: Sustainable Practices to Reduce Waste](https://www.plasticsengineering.org/events/spe-webinar-optimizing-plastic-color-formulation-sustainable-practices-to-reduce-waste/)
- [SPE COURSE: Discovering Unmet Customer Needs – A Fundamental Tool for Success in the Plastics Industry](https://www.plasticsengineering.org/events/spe-course-discovering-unmet-customer-needs-a-fundamental-tool-for-success-in-the-plastics-industry/)
- [SPE COURSE: Development of Architectural Polymers: Synthesis Strategies and Structure-Property Correlations](https://www.plasticsengineering.org/events/spe-course-development-of-architectural-polymers-synthesis-strategies-and-structure-property-correlations/)
- [SPE WORKSHOP: Introduction to Plastic Decorating Technologies](https://www.plasticsengineering.org/events/spe-workshop-introduction-to-plastic-decorating-technologies/)
- [SPE WORKSHOP: Navigating the Automotive Supply Chain: Engineering Electric Vehicle Batteries and Sustainable Manufacturing Practices](https://www.plasticsengineering.org/events/spe-workshop-navigating-the-automotive-supply-chain-engineering-electric-vehicle-batteries-and-sustainable-manufacturing-practices/)
- [SPE Plastics in Composites and Lightweighting](https://www.plasticsengineering.org/events/spe-plastics-in-composites-and-lightweighting/)
- [SPE COURSE: Trouble-Shooting Common Injection Molding Defects Through Virtual Molding](https://www.plasticsengineering.org/events/spe-course-trouble-shooting-common-injection-molding-defects-through-virtual-molding/)
- [SPE WORKSHOP: Harnessing Artificial Intelligence in Polymer Processing: Fundamentals and Practical Applications with a Focus on Injection Molding](https://www.plasticsengineering.org/events/spe-workshop-harnessing-artificial-intelligence-in-polymer-processing-fundamentals-and-practical-applications-with-a-focus-on-injection-molding/)
- [SPE COURSE: Thermoset Recycling](https://www.plasticsengineering.org/events/spe-course-failure-of-plumbing-parts/)
- [SPE COURSE: UV Effects on Plastic Materials](https://www.plasticsengineering.org/events/spe-course-uv-effects-on-plastic-materials/)
- [SPE COURSE: Advanced Thermal Packaging Using Phase Change Materials](https://www.plasticsengineering.org/events/spe-course-advanced-thermal-packaging-using-phase-change-materials/)
- [SPE COURSE: Thermoset Recycling](https://www.plasticsengineering.org/events/spe-course-thermoset-recycling/)
- [SPE COURSE: Mechanical Characterization of Additively Manufactured Polymers](https://www.plasticsengineering.org/events/spe-course-mechanical-characterization-of-additively-manufactured-polymers-2/)
- [SPE COURSE: Bio-plasticizers for PVC](https://www.plasticsengineering.org/events/spe-course-bio-plasticizers-for-pvc/)
- [SPE COURSE: Mechanical Characterization of Additively Manufactured Polymers](https://www.plasticsengineering.org/events/spe-course-mechanical-characterization-of-additively-manufactured-polymers/)
- [SPE COURSE: Rubber-O-Rings](https://www.plasticsengineering.org/events/spe-course-rubber-o-rings/)
- [SPE WEBINAR: Built to Last: Structural Thermoplastics for Hand and Power Tools](https://www.plasticsengineering.org/events/spe-webinar-built-to-last-structural-thermoplastics-for-hand-and-power-tools/)
- [SPE WORKSHOP: Mechanical and Chemical Recycling Overview for Polyolefins](https://www.plasticsengineering.org/events/spe-workshop-mechanical-and-chemical-recycling-overview-for-polyolefins/)
- [SPE Workshop: Consider Recycling More in the Equation in Addressing Future Polymer Design Requirements and Optimization](https://www.plasticsengineering.org/events/spe-workshop-consider-recycling-more-in-the-equation-in-addressing-future-polymer-design-requirements-and-optimization/)
- [SPE COURSE: PFAS in Products—Litigation Trends](https://www.plasticsengineering.org/events/spe-course-pfas-in-products-litigation-trends/)
- [SPE WORKSHOP: Failure in Plastics](https://www.plasticsengineering.org/events/spe-workshop-failure-in-plastics-2/)
- [SPE COURSE: Navigating Plastic Material Selection](https://www.plasticsengineering.org/events/spe-course-navigating-plastic-material-selection/)
- [SPE COURSE: Fourier Transform Infrared Spectroscopy in Failure and Compositional Analysis](https://www.plasticsengineering.org/events/spe-course-fourier-transform-infrared-spectroscopy-in-failure-and-compositional-analysis/)
- [SPE WORKSHOP: Troubleshooting in Injection Molding](https://www.plasticsengineering.org/events/spe-workshop-troubleshooting-in-injection-molding/)
- [SPE WEBINAR: Expanding Vinyl Material Characterization Capabilities: Showcasing a Rigid PVC Building Product Formulation](https://www.plasticsengineering.org/events/spe-webinar-expanding-vinyl-material-characterization-capabilities-showcasing-a-rigid-pvc-building-product-formulation/)
- [SPE WORKSHOP: Material Selection and Product Durability for Sustainable Plastics in Buildings and Infrastructures](https://www.plasticsengineering.org/events/spe-workshop-material-selection-and-product-durability-for-sustainable-plastics-in-buildings-and-infrastructures/)
- [ANTEC® 2025](https://www.plasticsengineering.org/events/antec-2025/)
- [SPE WEBINAR: The Challenges of Plastics Testing](https://www.plasticsengineering.org/events/spe-webinar-the-challenges-of-plastics-testing-2/)
- [SPE COURSE: Dynamic Mechanical Analysis](https://www.plasticsengineering.org/events/spe-course-dynamic-mechanical-analysis/)
- [SPE COURSE: Plastics Failures Associated with Injection Molding Issues](https://www.plasticsengineering.org/events/spe-course-plastics-failures-associated-with-injection-molding-issues/)
- [SPE WEBINAR: Advanced Material Characterization: Rheology and DMA Using a Combined Axial-torsional Multidrive System](https://www.plasticsengineering.org/events/spe-webinar-advanced-material-characterization-rheology-and-dma-using-a-combined-axial-torsional-multidrive-system/)
- [SPE WORKSHOP: Flexible Packaging Fundamentals: Converting and Performance Considerations](https://www.plasticsengineering.org/events/spe-workshop-flexible-packaging-fundamentals-converting-and-performance-considerations/)
- [Plastics in Sustainability: Biopolymers and Biocomposites](https://www.plasticsengineering.org/events/plastics-in-sustainability-biopolymers-and-biocomposites/)
- [SPE COURSE: Introduction to Ultraviolet (UV) Stabilization of Thermoplastics](https://www.plasticsengineering.org/events/spe-course-introduction-to-ultraviolet-uv-stabilization-of-thermoplastics/)
- [SPE COURSE: Material Characterization in Polymer Manufacturing: Addressing the Impact and Challenges of Recycled Materials](https://www.plasticsengineering.org/events/spe-course-material-characterization-in-polymer-manufacturing-addressing-the-impact-and-challenges-of-recycled-materials/)
- [SPE Conference: Per- and Polyflouralkyl Substances (PFAS) in the Plastics Industry 2024](https://www.plasticsengineering.org/events/spe-conference-per-and-polyflouralkyl-substances-pfas-in-the-plastics-industry-2024/)
- [SPE Workshop - Unlocking the Secrets of Plastics with Dynamic Mechanical Analysis](https://www.plasticsengineering.org/events/spe-workshop-unlocking-the-secrets-of-plastics-with-dynamic-mechanical-analysis/)
- [SPE WEBINAR: The Challenges of Plastics Testing](https://www.plasticsengineering.org/events/spe-webinar-the-challenges-of-plastics-testing/)
- [SPE Middle East Additives and Color Conference and PFAS Symposium](https://www.plasticsengineering.org/events/spe-middle-east-additives-and-color-conference-and-pfas-symposium/)
- [SPE WEBINAR: Increasing Polymer Sustainability Using AI](https://www.plasticsengineering.org/events/spe-webinar-increasing-polymer-sustainability-using-ai/)
- [SPE COURSE: Environmental Stress Cracking: The Plastics Killer](https://www.plasticsengineering.org/events/spe-course-environmental-stress-cracking-the-plastics-killer/)
- [SPE WORKSHOP: Controlling Energy Use in Plastics Processing](https://www.plasticsengineering.org/events/spe-workshop-controlling-energy-use-in-plastics-processing-3/)
- [SPE COURSE - Importance of Sustainable Practices in Plastics Technology: Consumer Preference and Brand Image](https://www.plasticsengineering.org/events/spe-course-importance-of-sustainable-practices-in-plastics-technology-consumer-preference-and-brand-image/)


## Landing Page


#
# Detailed Content


## Pages

- Published: 2023-06-12
- Modified: 2026-04-20
- URL: https://www.plasticsengineering.org/advertising/

Advertise With Us | Plastics Engineering menu Contact Advertising Trending Artificial Intelligence Business Design Editor’s Choice Technical Paper Education & Training Equipment Industry 4.0 Legal Analysis People PFAS Regulation Software Sustainability Industry Aerospace Automotive & Transportation Building & Construction Durables Electrical & Electronics Medical Packaging Sports & Recreation Toys Wearables Materials Additives & Colorants Composites Hydrogels Polyamide Resins Silicones Process 3D Printing/Additive Manufacturing Automation Auxiliaries Blow Molding Cast Film/Sheet Compounding Decorating & Coatings Extrusion Film Foam Processing Hybrid Manufacturing Injection Molding Mold & Die Making Recycling Rotational Molding Testing & Analysis Thermoforming All Articles Search Advertise with UsADVERTISE WITH US MEDIA KITPlastics Engineering reaches more vendors, products, and services than any other group in the plastics industry. 90% of our readership are leaders in decisions related to new plastics technologies 84% use Plastics Engineering content after reading it Over 22,500 of our readers are decision makers in the plastics industry 78% of our readers use Plastics Engineering media to learn about emerging technologies COVERAGE WORLDWIDESPE reaches over 60,000 plastics professionals worldwide. Plastics Engineering has the distinct advantage of providing content about new and emerging technologies to the innovators of the plastics industry. We develop enduring relationships with the industry leaders in plastics and find out about new advances first.CONTACT OUR TEAM First name * Last name * Country Company Email * Phone Subject *Your message * By using this form, you authorize us to use the information provided for the sole purpose of providing you with the correct answer. They...


- Published: 2023-06-02
- Modified: 2023-06-21
- URL: https://www.plasticsengineering.org/contact/

If you have any questions about Plastics Engineering, please fill out and submit the form below. To contact SPE, please visit www. 4spe. org/Contact. NOTE: If you are an SPE Chapter, Section or SIG looking to initiate a service request from SPE Headquarters, please go to www. 4spe. org/HQServices. Contact Our Team: First name * Last name * Email * Phone Subject... Accounting Annual Conference Awards Careers Chapter Meetings Digital Badging/BadgeCert Foundation General Leadership Media Membership PlastiVan Promote Your Business Publications Requesting a Technical Paper Scholarships SPE Store Subscribing to Plastics Engineering Magazine Unsubscribing from Plastics Engineering Magazine Website Your message * By using this form, you authorize us to use the information provided for the sole purpose of providing you with the correct answer. They will not be communicated to third parties. Know more about our privacy policy. Send


- Published: 2023-05-24
- Modified: 2023-06-21
- URL: https://www.plasticsengineering.org/privacy-policy-terms-of-use/

Privacy Statement Terms of Service Disclaimer How SPE Uses Your Personal Information Use of Likeness Secure Transactions Web Links to SPE Limitation of Liability Termination License to SPE Communities Subscribers Web Site Specific Issues Questions Summary The Data Privacy Policy is intended to provide the greatest possible access by SPE stakeholders to information in the Society's database. It also is prepared to be in compliance with applicable law. It is intended to ensure that SPE protects and ensures such data is used only within the framework of the SPE Data Use Policy. By accessing material on any of the SPE online platforms, you: Acknowledge that SPE owns the copyright in or has permission to use all materials displayed on this site. You are authorized to read and use this information for your personal use. You are not authorized to share the materials on SPE Online with others by copying or sending it to them. You can tell colleagues where they can find this material for themselves. The materials displayed on the SPE web site are protected by federal copyright law. Agree that if you choose to use the communications tools provided, including email and list servers, you give SPE full and unrestricted permission to use and republish any materials that you post to the site in any way SPE deems fit, without compensation to you. You may not post anything to the site that is unlawful, obscene, defamatory, or offensive. You may not use this site to exploit any commercial...




## Posts

- Published: 2026-08-07
- Modified: 2026-08-03
- URL: https://www.plasticsengineering.org/2026/08/digital-process-control-supports-stable-molding-of-pcr-and-pir-011843/
- Categories: Artificial Intelligence, Automotive & Transportation, Building & Construction, Business, Durables, Electrical & Electronics, Equipment, Industry, Industry 4.0, Injection Molding, Materials, Medical, Process, Recyclate, Recycling, Resins, Sensors, Software, Sustainability, Trending
- Tags: Arburg

Smart controls and modified plasticizing systems help stabilize recyclate injection molding despite variations in viscosity and feedstock.

Smart controls and modified plasticizing systems help stabilize recyclate injection molding despite variations in viscosity and feedstock. Processing post-industrial recyclate (PIR) and post-consumer recyclate (PCR) requires process adjustments because material properties can vary considerably. Arburg has developed several control concepts that help maintain constant mold filling. Through its digital pilot functions, the German machine manufacturer maintains stable injection molding during both injection and holding pressure. You can also read: The Complexity of Recyclate. These pilot functions can counteract fluctuations in melt viscosity during processing. The aXw Control ReferencePilot and aXw Control RecyclatePilot detect and compensate for irregularities while controlling the ongoing injection process. As a result, processors can keep mold filling as constant as possible and maintain consistent part quality despite major material variations. Feeding the Unstable In conventional injection molding, processors usually feed the machine with granules. However, the shape and quality of the feedstock directly affect the production process. When processors use flakes, they can expect large variations in both size and shape. Reground material behaves differently. It comes from plastic parts shredded with a sprue grinder. Ideally, this material contains particles between two and five millimeters. However, these particles usually contain finer material, such as dust-like fractions. To ensure a stable melting process, processors must remove this dust from the regrind. For processing regrind and flakes, Arburg offers a retrofittable recyclate package that combines hardware and software features. A modified cylinder module enables uninterrupted feeding, even when materials flow poorly. In addition, a plasticizing screw with a...


- Published: 2026-08-06
- Modified: 2026-08-03
- URL: https://www.plasticsengineering.org/2026/08/plastics-in-menstrual-products-performance-safety-and-sustainability-011835/
- Categories: Circular Economy, Design, Film, Industry, Injection Molding, Materials, Medical, Microplastics, Packaging, People, PFAS, Polyolefins, Process, Regulation, Resins, Sustainability, Thermoplastics, Trending
- Tags: plastic waste

Plastics in menstrual products affect hygiene, comfort, additive exposure, PFAS concerns, and environmental impact.

Plastics in menstrual products affect hygiene, comfort, additive exposure, PFAS concerns, and environmental impact. Feminine hygiene, or menstrual products, is often a taboo subject, even though half of the world’s population experiences menstruation. Even so, the Smithsonian Museum identified that the global industry is worth an estimated 15 billion USD. With such a large market share, the spotlight on menstrual plastics, particularly their safety and environmental impact, has risen quickly. You can also read: Team Designs Digital Health Tools for Pregnant Refugees. Though most are familiar with today’s plastic, compact tampon and thin absorbent pads, their predecessors were not as convenient. Before the advent of commercial feminine hygiene products, women used pieces of cloth to absorb menstrual fluid, then washed and reused these clothes. The introduction of plastics in packaging, product manufacturing, and effectiveness was not explored seriously until the 1970s. By prioritizing women’s health and integrating plastics research, products are now commercially available. Construction of Menstrual Products Menstrual products range from single-use items like pads, liners, and tampons to reusable items like menstrual cups, underwear, and some pads. Though all these products’ purposes are similar, to absorb or collect menstrual fluid, the function of plastics varies. Summary of the menstrual product variety used among still menstruating (pre-menopausal) participants. The study was a “choose all that apply” questionnaire, therefore the sum of the percentages does not equal 100%. Courtesy of Harvard University School of Public Health. Packaging for Sanitary Protection Most products are packaged with external wrappings to protect them...


- Published: 2026-08-06
- Modified: 2026-08-05
- URL: https://www.plasticsengineering.org/2026/08/recycled-plastics-in-electronics-housings-face-heat-and-compliance-limits-011792/
- Categories: Circular Economy, Electrical & Electronics, Industry, Injection Molding, Materials, Nylons, PET, Polycarbonate, Polyethylene, Polyolefins, Polypropylene, Process, Recyclate, Recycling, Regulation, Resins, Sustainability, Thermoforming, Thermoplastics, Vinyl
- Tags: Dimensional Stability, Flame Retardants, Mechanical Recycling, polymer degradation

Recycled plastics can support electronics housings, but heat, impact, flame ratings, and compliance still limit adoption.

Recycled plastics can support electronics housings, but heat, impact, flame ratings, and compliance still limit adoption. Electronics housings are high-volume injection-molded parts commonly made from ABS, HIPS, PC, PC/ABS, PP, and filled compounds. These polymers also appear in WEEE streams, which makes recycled content a relevant route for material recovery. However, housings must do more than define the enclosure shape. They need screw-boss integrity, dimensional stability, localized heat resistance, and reliable flame performance. For recycled compounds, these requirements call for tight control of feedstock composition, additive history, and batch-to-batch variability. You can also read: Repair or Recycle? Rethinking Electronics Design From Recycled Content to Material Qualification Shredded plastic fractions from electronic waste can vary in polymer type, color, additive package, and contamination level, which makes feedstock control essential before reuse in electronics housings. Courtesy of AMD. Waste electrical and electronic equipment, or WEEE, contains valuable plastic fractions that can support closed-loop or semi-closed-loop recycling. However, these streams rarely arrive as clean single-polymer feedstocks. They often contain mixed polymers, pigments, fillers, stabilizers, impact modifiers, flame retardants, and contamination from dismantling and shredding. This variability complicates qualification. Additive complexity is especially important in electronics because legacy flame-retardant systems can affect both processing and regulatory compliance. Mixed polymer fractions can also shift melt flow, reduce impact strength, increase brittleness, or create surface defects in molded parts. For housings, this variability matters because failures often initiate at localized features rather than in the bulk wall section. Recycled compounds must retain modulus, impact strength, heat-deflection...


- Published: 2026-08-05
- Modified: 2026-07-27
- URL: https://www.plasticsengineering.org/2026/08/introduction-to-pvc-gelation-and-formulation-fusion-additives-and-processing-012061/
- Categories: Building & Construction, Editor's Choice Technical Paper, Education & Training, Extrusion, Foam Processing, Industry, Materials, Process, Resins, Thermoplastics, Vinyl
- Tags: Plastics Engineering

PVC remains one of the world's most versatile and widely used polymers, but producing high-performance PVC products requires far more than selecting the right resin. From pipe and window profiles to foam board and flooring, success depends on understanding the relationship between gelation, fusion, additives, and processing conditions.

PVC gelation, fusion, additives, and processing conditions influence torque, thermal stability, surface finish, and mechanical performance. Polyvinyl chloride (PVC) remains one of the world's most versatile and widely used polymers, but producing high-performance PVC products requires far more than selecting the right resin. From pipe and window profiles to foam board and flooring, success depends on understanding the relationship between gelation, fusion, additives, and processing conditions. You can also read: Advancing PVC Processing with Tung Oil-Based Heat Stabilizers. In a recent technical presentation, PVC experts explored the science behind gelation and formulation, offering a detailed look at how processors can optimize mechanical properties, thermal stability, surface finish, and long-term performance. The discussion highlighted why PVC continues to be a cornerstone material across the building and construction industry and why understanding its processing behavior remains essential for plastics engineers. What Is PVC Gelation? One of the most important distinctions in PVC processing is the difference between gelation and fusion—two terms often used interchangeably but representing different phenomena. Gelation refers to the breakdown of PVC powder particles and the subsequent entanglement of polymer chains. Fusion, meanwhile, describes the processing stage where those particles become a homogeneous melt during extrusion or mixing. Together, they determine the final performance of the finished article. Unlike many thermoplastics, suspension PVC begins as particles approximately 100–200 microns in diameter with a distinctive "popcorn-like" morphology. Beneath the particle's outer skin lie primary particles roughly one micron in size. During processing, heat and shear break apart the outer structure,...


- Published: 2026-08-04
- Modified: 2026-07-27
- URL: https://www.plasticsengineering.org/2026/08/polymer-coating-improves-flame-retardancy-in-bamboo-011831/
- Categories: Additives & Colorants, Composites, Decorating & Coatings, Design, Durables, Education & Training, Industry, Materials, Process, Resins, Sustainability, Trending
- Tags: sustainable materials

A composite polymer coating improves bamboo flame retardancy, water resistance, char formation, and smoke suppression.

A composite polymer coating improves bamboo flame retardancy, water resistance, char formation, and smoke suppression. Bamboo is an abundant, rapidly growing renewable resource. When processed into recombined bamboo (RB), the material’s increased strength makes it a suitable replacement for plastic in certain applications. Nevertheless, bamboo has poor water resistance and is inherently flammable, limiting its uses. Many coatings currently used for bamboo products offer flame retardancy but lack water resistance, or vice versa. To enhance the applications of bamboo products, there is a need for a coating that addresses both limitations. In a recent study, researchers engineered a composite coating to optimize flame retardancy and water resistance in RB. You can also read: Limiting Volatile Organic Compounds in PP Wood-Plastic Composites Coating Preparation Researchers developed this coating using commercial fluorocarbon (FC) and PolyX (X = 1, 2, 3), a self-synthesized flame-retardant copolymer. Alone, FC increases flammability, but the FC component is crucial for the coating’s water resistance. Because FC-based materials are persistent in the environment, this formulation incorporates it only as a minor component. This allows the coating to achieve hydrophobic and barrier performance while reducing the environmental burden associated with high-PFAS coatings. The composite coating, referred to as FPX, is comprised of PolyX (X = 1, 2, 3) and FC. Figure courtesy of Synergistically engineered multifunctional composite coating for recombined bamboo with optimized flame retardancy, water resistance and thermal insulation performance. Researchers prepared samples with hydroxyethyl acrylate:sodium vinyl sulfonate (HEA:VS) ratios of 50:50, 45:55, and 40:60, which they referred...


- Published: 2026-08-03
- Modified: 2026-07-23
- URL: https://www.plasticsengineering.org/2026/08/melt-filtration-becomes-critical-for-recycled-abs-quality-011798/
- Categories: Aerospace, Automotive & Transportation, Durables, Education & Training, Equipment, Industry, Materials, Process, Recyclate, Recycling, Resins, Sustainability, Thermoplastics
- Tags: polymer degradation, recycled content

Melt filtration affects ABS recyclate quality, pressure stability, contaminant removal, melt flow, and the risk of polymer degradation.

Melt filtration affects ABS recyclate quality, pressure stability, contaminant removal, melt flow, and the risk of polymer degradation. As processors increase recycled content, melt filtration becomes more than a contamination-control step. It also affects pressure stability, residence time, material degradation, and final part properties. In recycling lines, screen selection can influence both melt quality and process reliability. Recent research examined how selected particulate contaminants and different melt-screen sizes affected ABS and ABS recyclate. The study focused on contaminants that can appear in recycled streams, including wood and rubber particles, and compared post-consumer ABS recyclate filtered through screens with mesh sizes of 250, 100, 60, and 20 μm. You can also read: Conveying PCR: Reducing Fines, Angel Hair, and Scrap. Why Contamination Still Matters Effect of particulate contaminants on the strain at break of ABS. Courtesy of Influence of selected contaminations and melt filtration on the properties of ABS and ABS recyclate. Recycled polymers can retain low concentrations of particulate contaminants after sorting, washing, and size reduction. Although these residues may not appear during routine visual inspection, they can influence melt processing behavior and reduce mechanical performance. In the study, low concentrations of model contaminants measurably reduced key ABS properties. Wood and rubber particles added at 0. 5 to 2. 0 wt. % decreased material performance, with a stronger effect on ductility-related properties. This finding matters for processors because recycled-content evaluation often emphasizes melt flow, color, and visible contamination. However, residual particulates can also reduce toughness and elongation, directly affecting the...


- Published: 2026-07-31
- Modified: 2026-07-22
- URL: https://www.plasticsengineering.org/2026/07/recovering-high-purity-pc-abs-from-end-of-life-vehicles-011820/
- Categories: Automotive & Transportation, Business, Circular Economy, Design, Education & Training, Industry, Materials, Polycarbonate, Process, Recycling, Recycling, Resins, Sustainability, Thermoplastics, Trending
- Tags: Circular Economy

In a project with Audi AG, Fraunhofer IVV demonstrated how solvent-based recycling can recover high-quality PC/ABS from automotive waste.

In a project with Audi AG, Fraunhofer IVV demonstrated how solvent-based recycling can recover high-quality PC/ABS from automotive waste. European regulators are increasing circularity requirements for the automotive industry. A current draft states that around 25% of a vehicle’s plastic weight should come from post-consumer recycled material. It also states that one-quarter of that recycled content should come from end-of-life vehicles. Therefore, manufacturers need to recycle components from current vehicles and develop new parts from PCR sources. However, automotive components often combine several materials. This complexity makes conventional sorting and mechanical recycling more difficult. You can also read: Machines Can Be Smart Fraunhofer IVV has developed a physical dissolution process to clean and recover thermoplastics from sorted plastic waste streams. In collaboration with CreaCycle GmbH, the institute released solvent formulations under the CreaSolv brand. These formulations separate specific plastics from heterogeneous input streams. Tackling PCR in Automotive Applications Fraunhofer IVV, Audi AG, and other industry partners are sorting, separating, and cleaning technical thermoplastics from shredder residue fractions. They use a solvent-based recycling process to obtain pure recyclates for new automotive components. In the first stage, researchers cleaned plastic-rich fractions from shredded Audi vehicles. Then, they used spectroscopic sorting to remove non-plastic materials, including glass, metals, fibers, and wood. Early results showed that density sorting could separate valuable metals and produce recyclable plastic fractions. However, the process worked best when researchers combined density sorting with X-ray spectroscopy, laser spectroscopy, and tribo-electrostatic techniques. The thermoplastic fraction contained PP, fiber-reinforced PP, PC, ABS,...


- Published: 2026-07-30
- Modified: 2026-07-16
- URL: https://www.plasticsengineering.org/2026/07/basf-and-eth-zurich-advance-mixed-plastic-waste-gasification-011813/
- Categories: Automotive & Transportation, Business, Circular Economy, Composites, Industry, Materials, Polyolefins, Process, Recyclate, Recycling, Recycling, Resins, Results, Sustainability, Thermoplastics, Thermosets, Trending
- Tags: BASF, Chemical Recycling, Circular Economy, Recycled plastics

Gasification of automotive shredder plastic with biomass lowers CO₂ emissions and creates circular feedstock for chemical production.

Gasification of automotive shredder plastic with biomass lowers CO₂ emissions and creates circular feedstock for chemical production. BASF has worked with ETH Zurich to recycle automotive shredder residue combined with bio-waste. Together, they aim to transform these materials into high-value chemical feedstock. The research demonstrates the technical feasibility of chemical recycling through gasification for mixed plastic waste. The ETH study follows a 2025 gasification pilot project conducted by BASF and BEST GmbH, an Austrian-based company. During the project, BEST treated plastic waste from automotive shredder residue, along with biomass, at its gasification pilot plant. You can also read: Chopped Fiber Compounding Enters Injection Molding. Instead of incinerating plastics and biomass to generate electricity and steam, co-gasification produces steam and synthesis gas. This synthesis gas serves as a valuable feedstock for chemicals. Therefore, it can replace fossil resources, lower emissions, and keep carbon in the loop. “Closing the carbon loop by plastics recycling is not only beneficial for the climate but also crucial for conserving resources, an essential step toward a plastics industry that operates within planetary boundaries,” says André Bardow, professor at ETH Zurich. The results are promising. Recycling 1 kg of automotive shredder residue with 3 kg of biomass reduces greenhouse gas emissions by more than 3 kg CO₂-eq. This reduction was measured against incineration with energy recovery on a cradle-to-gate basis. A Promising Start The first pilot project also involved Porsche AG and focused on the recovery of automotive shredder residue. This stream includes plastic, film, paint, and...


- Published: 2026-07-29
- Modified: 2026-07-16
- URL: https://www.plasticsengineering.org/2026/07/2026-injection-molding-summit-spotlights-metal-3d-printing-012006/
- Categories: Business, Design, Education & Training, Equipment, Injection Molding, Mold & Die Making, People, Process, SPE News

SPE’s 2026 Injection Molding Innovation Summit will feature Xact Metal in a panel on moldmaking with metal 3D printing.

SPE’s 2026 Injection Molding Innovation Summit will feature Xact Metal in a panel on moldmaking with metal 3D printing. Metal additive manufacturing continues to move from prototyping into production tooling, and its value becomes especially clear when cooling limits injection molding performance. You can also read: Metal 3D Printing in Mold Making: A Technologies Comparison. At the 2026 Injection Molding Innovation Summit, SPE will close its technical agenda with a panel on “Moldmaking with metal 3D printing. ” The session will feature Scott Kraemer of Xact Metal, Scott Peters of Molded Marketing LLC, and another speaker still to be confirmed. The topic fits naturally within a program focused on simulation, digital twins, automation, cavity pressure, foam molding, and workforce training. Together, these sessions show how molders now use data, software, and advanced tooling to reduce risk before production begins. Register for the event here. Why Cooling Still Defines the Cycle Injection molders often focus on machines, materials, and process windows. However, the mold itself still controls much of the cycle. Cooling time typically accounts for a significant portion of the injection molding process, particularly for thick or complex parts. Therefore, even small cooling improvements can create meaningful productivity gains without changing the resin, press, or molding cell. Conventional cooling channels, however, limit mold designers because drilled lines must follow straight paths. As a result, these channels cannot always reach hot spots near critical surfaces, threads, ribs, or thick sections. Consequently, that limitation often forces molders to extend cooling time, even...


- Published: 2026-07-29
- Modified: 2026-07-29
- URL: https://www.plasticsengineering.org/2026/07/pfas-rules-are-reshaping-fluoropolymer-selection-011486/
- Categories: Automotive & Transportation, Durables, Electrical & Electronics, Industry, Materials, Medical, PFAS, Regulation, Trending

PFAS regulation is changing fluoropolymer selection by separating applications into essential, replaceable, and politically exposed uses.

PFAS regulation is changing fluoropolymer selection by separating applications into essential, replaceable, and politically exposed uses. PFAS regulation now pushes fluoropolymer selection toward a narrower technical test. The question is no longer only whether a material delivers the required part performance. The question is whether the application depends on a combination of properties that alternative materials still cannot match within the same operating window. That includes chemical resistance, thermal stability, dielectric performance, purity, permeation resistance, and long-term durability under aggressive service conditions. This matters because fluoropolymers do not behave as a single class. PTFE, PFA, FEP, PVDF, and ETFE differ in melt processability, crystallinity, dielectric response, permeability, and heat and chemical resistance. These differences now shape a more practical sorting logic across fluoropolymer applications. You can also read: Fluoropolymers Life Cycle and PFAS Contamination. Essential Uses Fluoropolymers remain important in semiconductor applications that require high purity, chemical resistance, and process reliability. Courtesy of ECt. The first bucket is essential uses. These applications depend on fluoropolymer property sets that remain difficult to replace without a measurable loss in reliability, cleanliness, thermal margin, or service life. The technical case is strongest where failure would compromise process integrity or device function. Semiconductor fluid handling is a clear example. High-purity tubing, valves, seals, and vessel components often require very low extractables, resistance to strong acids and solvents, and stable performance under tightly controlled process conditions. Medical applications fall into the same category when the material must combine lubricity, chemical inertness, sterilization tolerance, flexural durability,...


- Published: 2026-07-28
- Modified: 2026-07-28
- URL: https://www.plasticsengineering.org/2026/07/3-ways-to-reduce-cycle-time-in-injection-molding-011825/
- Categories: Business, Equipment, Industry, Injection Molding, Materials, Mold & Die Making, Process, Resins, Results, Software, Strategy, Thermoplastics, Trending
- Tags: Cycle Time Reduction, Process Optimization

Reducing melt overheating, back pressure, and poor mold cooling can shorten cooling time and improve injection molding efficiency.

Reducing melt overheating, back pressure, and poor mold cooling can shorten cooling time and improve injection molding efficiency. When quoting a new injection-molded component, processors often set the cycle time based on previous experience or similar parts. Once the process is parameterized to meet that cycle time, however, it is often no longer challenged. You can also read: Plastics Injection Molding: Definition, Benefits and Applications https://youtu. be/5B6pHIKGBi4? si=zpnP31bK6eTOWqQQ During my consulting work, I frequently find opportunities to improve cycle time. My first piece of advice is always the same: reduce the amount of energy entering the system. The more heat you carry inside the component, the longer it will take to cool. Therefore, when looking for opportunities to reduce cycle time, examine the process stages where you may be inadvertently supplying more heat to the melt than necessary. Heat obviously comes from the heater bands around the plasticizing unit. However, the largest amount of heat often comes from friction. Take Care of the Temperature Profile The curve depicts the mean temperature of a molded component over cycle time, at two different initial melt temperature conditions. . The lower de initial melt temperature, the faster the ejection temperature is achieved. Courtesy of PM TEC Engineering. The first step to avoid overheating the melt is to reduce the heat supplied by the plasticizing unit's temperature profile. In a general-purpose screw under regular operating conditions, processors normally use a temperature profile that starts lower at the feed throat and increases toward the nozzle....


- Published: 2026-07-27
- Modified: 2026-07-16
- URL: https://www.plasticsengineering.org/2026/07/recycled-automotive-plastics-face-cabin-grade-challenges-011774/
- Categories: Automotive & Transportation, Circular Economy, Decorating & Coatings, Design, Elastomers, Finishing, Industry, Injection Molding, Materials, People, Process, Recycling, Resins, Semi-Finished Products, Silicones, Sustainability, Thermoplastics, Trending
- Tags: circularity, Injection Molding, plastic recycling, polymer processing

Circularity targets are moving recycled polymers into more automotive applications, but vehicle cabins remain among the most demanding.

Circularity targets are moving recycled polymers into more automotive applications, but vehicle cabins remain among the most demanding. Recycled plastics can meet many automotive requirements when the part stays hidden. A bracket, battery housing, or under-the-hood component can tolerate small changes in color, gloss, or surface feel if the material meets mechanical and thermal targets. Cabin interiors offer far less forgiveness. In the vehicle cabin, recycled polymers must meet a different set of performance standards. They must look consistent, feel controlled, process reliably, and release minimal odor or volatile compounds. A resin that performs well in a structural application may still fail when it becomes a dashboard skin, door trim, console surface, pillar cover, or other visible touchpoint. The main barrier is not whether recycled polymers can enter mobility interiors, but whether they can deliver repeatable sensory and aesthetic performance at production scale. You can also read: Reactive Extrusion for PCR Odor Control. Why Hidden Parts Are Easier Than Cabin Parts Automotive plastics already carry a heavy sustainability burden. OEMs now specify recycled content for structural parts, battery housings, and under-the-hood components. In these applications, surface appearance plays a limited role, and some material variation remains acceptable. A small shift in gloss or color matters less when the part sits behind an engine block. Cabin interiors follow a different standard. Visible and touchable surfaces must meet strict requirements for color, gloss, texture, odor, and emissions. Drivers and passengers interact with these materials every day, so small defects become easy to...


- Published: 2026-07-24
- Modified: 2026-07-14
- URL: https://www.plasticsengineering.org/2026/07/polymer-coated-proppants-improve-hydraulic-fracturing-performance-011751/
- Categories: Adhesives, Building & Construction, Business, Cast Film/Sheet, Decorating & Coatings, Education & Training, Energy Generation, Finishing, Industry, Materials, Process, Regulation, Resins, Results, Sustainability, Thermoplastics, Trending
- Tags: Polymer Composites

Engineers upgrade polymer proppants to safely boost fracturing flow, quickly cut wear, and improve thermal yields for commercial oil wells.

Engineers upgrade polymer proppants to safely boost fracturing flow, quickly cut wear, and improve thermal yields for commercial oil wells. Energy extraction companies lose massive revenue when traditional bare proppants fail under immense subterranean pressure. Without protective layers, extreme compression crushes the brittle ceramic beads, causing catastrophic wellbore blockages. Engineers solve this costly structural failure by encasing ceramsite particles in advanced epoxy resins. By modifying the underlying tribological physics, these specialized coatings help operators lock proppants deep within subterranean shale fractures, ensuring sustained oil flow and securing long-term operational profitability. You can also read: From Crude to Cost: The Oil-Plastic Price Connection. Controlling Mechanical Surface Wear To understand how these protective coatings survive extreme environments, tribologists analyze the precise surface friction occurring under simulated downhole conditions. Bare ceramsite particles (CP) grind aggressively against the rigid shale surfaces during high-velocity injection. This raw kinetic interaction creates massive debris fields that quickly clog the delicate hydrocarbon fluid channels. When manufacturers apply a uniform epoxy resin layer over the ceramic core (PCP), the polymer physically buffers the violent contact zone. During initial injection phases, the resilient polymer coating deliberately sacrifices its outer micro-layers. This planned sacrificial degradation absorbs the abrasive shockwaves and fully protects the dense structural integrity of the inner ceramic bead. This specific friction-mitigation mechanism prevents catastrophic particle crushing, reduces equipment maintenance costs, and maintains optimal fluid conductivity within newly expanded shale cracks. (a) The schematic diagram of PCP movement in the crack along with the fracturing fluid (GG). (b) The...


- Published: 2026-07-23
- Modified: 2026-07-16
- URL: https://www.plasticsengineering.org/2026/07/pla-foam-aircraft-wings-use-nature-inspired-design-011770/
- Categories: 3D Printing/Additive Manufacturing, Aerospace, Design, Industry, Materials, Process, Resins, Thermoplastics, Trending
- Tags: additive manufacturing

Inspired by the porous bones of birds, these porous materials offer a new design framework for aircraft wings.

Inspired by the porous bones of birds, these porous materials offer a new design framework for aircraft wings. Learning from Bird Bone Structures The bones of flying birds are composed of external shells reinforced by internal cellular microstructures. This structure allows for low density while still retaining sufficient stiffness and strength to carry aerodynamic loads. Similar low-density, high-strength structures have garnered attention in the aerospace, automotive, biomedical, and robotic fields. Cellular structures provide a high stiffness-to-weight ratio while also reducing material use. You can also read: Designing the World’s Largest Aircraft Through Smart Structural Analysis. Figure 1 – The internal structure of vulture bones (a) is a source of inspiration for researchers designing aircraft wings. Figure courtesy of Optimization, additive manufacturing, and testing of bird-bone-inspired materials for aircraft wing designs. Printing Complex Wing Structures The morphologies of these bird-bone-inspired materials cannot be fabricated using traditional manufacturing methods. Additive manufacturing can overcome these limitations, but printed parts often exhibit anisotropy. Weaker bonding between printed layers than within layers can lead to directional differences in mechanical properties. When designing plastic parts using additive manufacturing, engineers must take this into consideration. When developing the design and optimization framework for bird-bone-inspired aircraft wings, researchers employed fused deposition modeling (FDM). The printing process significantly influences the mechanical properties of FDM parts. Thus, this framework accounted for anisotropy in these complex cellular lattices and closed-cell foams. Optimizing the Wing Interior Researchers chose a small-scale wing geometry based on unmanned aerial vehicle (UAV) designs. Unlike larger aircrafts,...


- Published: 2026-07-23
- Modified: 2026-07-23
- URL: https://www.plasticsengineering.org/2026/07/elevate-your-career-with-spes-essentials-of-management-leadership-in-plastics-001766/
- Categories: SPE News
- Tags: SPE News

If you are aspiring to move into a leadership position within your company, whether it involves managing teams or projects, SPE's Essentials of Management & Leadership in Plastics is ideal for you to refine your leadership skills.

If you are aspiring to move into a leadership position within your company, whether it involves managing teams or projects, SPE's Essentials of Management & Leadership in Plastics is ideal for you to refine your leadership skills. Transitioning from being a successful individual contributor to a strong manager is undoubtedly a challenging journey—it could be the most daunting shift for any leader. SPE's Essentials of Management & Leadership in Plastics is a comprehensive six-month online cohort-based program scheduled to start in October 2026 and continue through Spring of 2027. This program is designed to equip early to mid-level career professionals in the plastics industry with the essential skills and knowledge required for leadership roles. Throughout the program, participants will delve into critical leadership topics, including strengths-based leadership, strategic planning, organizational culture, innovation, basic financial literacy, leader awareness, and boundaries. By the end of the program, participants will not only receive a digital credential but will also be fully prepared to navigate volatile, uncertain, complex, and ambiguous (VUCA) environments, actively engage in strategic planning, collaborate effectively with cross-functional teams, and demonstrate financial acumen. https://www. youtube. com/watch? v=EKwrUd0DCQQ&t=15s Here are some compelling reasons why enrolling in the Essentials of Management & Leadership in Plastics program can lead to becoming a successful leader in the plastics industry: Enhance Your Management Skills: The program focuses on improving your ability to strategize, communicate, think critically, manage time, and lead teams and projects effectively, making you a more valuable asset within your company. Gain Practical Knowledge:...


- Published: 2026-07-22
- Modified: 2026-07-16
- URL: https://www.plasticsengineering.org/2026/07/recycled-cobalt-pigment-adds-color-and-flame-retardancy-to-pla-011765/
- Categories: Additives & Colorants, Aerospace, Automotive & Transportation, Building & Construction, Compounding, Design, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Industry, Materials, Packaging, People, Process, Regulation, Sustainability, Toys, Wearables
- Tags: Thermal Stability

Researchers synthesized a cobalt aluminate pigment (CoAL2O4) that acts as both a flame retardant and colorant in polylactide (PLA).

Researchers synthesized a cobalt aluminate pigment (CoAL2O4) that acts as both a flame retardant and colorant in polylactide (PLA). Recently, researchers developed a method for synthesizing a stable blue cobalt pigment using aluminum from recycled can seals. The resulting material, CoAL2O4, has a spinel form, which allows insertion of chromophore ions. Insertion of these ions provides intense color, high thermal stability, and chemical resistance. The strategy is based on doping metal oxides with chromophore ions and transition metals. Thus, it is easy to control the pigment’s chemical composition. You can also read: Setting the Tone with Functional Pigments Supporting Circular Flame-Retardant Additives Composite metal oxide pigments, which have multiple metal constituents, exhibit significant benefits over single metal oxides. With superior opacity, thermal stability, infrared properties, and weather- and chemical-resistance, they are beneficial for a variety of applications. One such composite metal oxide pigment, cobalt aluminate, has flame-retardant properties and provides an intense blue pigment. In a recent study, researchers adapted the cobalt pigment into a brightly-colored flame retardant for PLA. This sustainable additive, synthesized from recycled materials, aligns with circular economy principles. Furthermore, researchers see this PLA composite as a candidate for three-dimensional (3D) printing applications. Researchers tailored the CoAL2O4 pigment for use as a flame retardant. Figure courtesy of Two in One: Recycled Cobalt Aluminate as a Pigment and Synergistic Flame-Retardant Agent for Polylactide. Synthesizing Cobalt Aluminate from Recycled Materials Researchers recycled aluminum can seals using hydrochloric acid to form a solution containing Al3+ ions. Then, they added sodium...


- Published: 2026-07-21
- Modified: 2026-07-15
- URL: https://www.plasticsengineering.org/2026/07/memory-polymers-preventing-aneurysm-recurrence-in-endovascular-care-010899/
- Categories: 3D Printing/Additive Manufacturing, Composites, Design, Editor's Choice Technical Paper, Education & Training, Equipment, Foaming Agents, Hybrid Manufacturing, Hydrogels, Industry, Materials, Medical, People, Process, Sensors, Silicones, Thermoplastics, Trending
- Tags: medical devices

Shape memory polymers expand massively to eliminate aneurysm recurrence. Engineers utilize entropic recovery to optimize endovascular devices.

Shape memory polymers expand massively to eliminate aneurysm recurrence. Engineers utilize entropic recovery to optimize endovascular devices. Surgeons often struggle with bare-metal platinum coils because these traditional devices leave structural gaps. Consequently, aneurysm recurrence rates reach 30%. To eliminate these failures, engineers utilize shape memory polymers driven by entropic recovery. Specifically, material scientists store polymer chain segments in a high-energy, non-equilibrium temporary shape. Then, once surgeons expose the device to body heat, the chains spontaneously reorganize into their thermodynamically preferred, high-entropy original shape. You can also read: Innovative Hydrogel Coatings for Medical Catheters Molecular Architecture and Actuation Engineers build shape-memory polymers using architectures that combine molecular switches and network points. Switches fix the temporary shape as the material undergoes vitrification. Netpoints remember the permanent shape through dipole-dipole interactions, van der Waals forces, or hydrogen bonding. Manufacturers create these structures using either physically cross-linked co-polymers, such as polyurethanes with soft and hard segments, or chemically cross-linked glassy thermosets that rely on reversible covalent bonds. Schematic of two potential approaches to fabricate shape memory polymer (SMP)-based endovascular devices for ICA treatment: (a) SMP-coated coils; and (b) SMP coil-free foams with patient-specific geometries. Courtesy of Shape Memory Polymer-Based Endovascular Devices: Design Criteria and Future Perspective To ensure safe thermomechanical recovery, developers tune the glass transition or melting temperature to the physiological range of 30–37 °C. Production teams fabricate porous structures using gas-foaming agents or solid-particle leaching. During leaching, technicians dissolve dispersed particles, such as sodium chloride, after curing to create porous gaps. These...


- Published: 2026-07-20
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/core-shell-flame-retardant-reduces-migration-in-pa66-011756/
- Categories: Additives & Colorants, Aerospace, Automotive & Transportation, Composites, Decorating & Coatings, Design, Durables, Editor's Choice Technical Paper, Finishing, Industry, Materials, People, Process, Regulation, Resins, Semi-Finished Products, Thermoplastics, Trending

Researchers developed a promising solution to prevent flame retardant migration in Polyamide 66 (PA66) while increasing durability.

Researchers developed a promising solution to prevent flame retardant migration in Polyamide 66 (PA66) while increasing durability. Halogen-free flame retardants avoid generating the toxic and corrosive gases released by their halogen-containing counterparts during degradation. Nevertheless, they tend to migrate to high-temperature, high-humidity environments. To combat this migration, researchers developed SiR@RF, a core-shell elastic flame retardant. This novel material demonstrated improved fire safety in Polyamide 66 (PA66). You can also read: Potential of Microencapsulated Flame Retardants. PA66 has a wide range of uses in the automotive, electrical, and aerospace industries. This high-performance engineering thermoplastic provides good mechanical properties, thermal stability, and chemical resistance. It is inherently flammable, necessitating a solution to improve its fire resistance and enable its use in more applications. Additionally, aluminum diethylphosphinate (ADP) and melamine polyphosphate (MPP) in PA66 can migrate to its surface under certain environmental conditions. This visually alters the material, giving it a white, frost-like appearance. Encapsulating Flame Retardants To mitigate migration in PA66, researchers used polymethylsiloxane (SiR) to encapsulate the flame retardants. SiR is thermally stable, hydrophobic, and elastic, with vinyl groups working as cross-linking sites. Researchers produced X-SiR@FR samples with an “X” mass fraction of SiR in a mixture of ADP and MPP. Figure courtesy of A Core–Shell Elastic Flame Retardant with Superior Migration Resistance for Fire-Safe and Toughened Polyamide 66. Using scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS), researchers analyzed the shell’s impact on the flame retardant’s microstructure. In 9-SiR@FR, they observed a significant particle size increase. Particle aggregation indicated...


- Published: 2026-07-17
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/optimizing-tpu-durability-for-medical-devices-011747/
- Categories: Cast Film/Sheet, Composites, Design, Editor's Choice Technical Paper, Elastomers, Equipment, Industry, Materials, Medical, Mixing & Blending, People, Polyurethane, Process, Sustainability, Testing & Analysis, Trending
- Tags: Medical Plastics, polymer processing

Engineers optimize TPUs with novel antimicrobial fillers and surface methods, improving commercial medical device manufacturing and preventing material failures.

Engineers optimize TPUs with novel antimicrobial fillers and surface methods, improving commercial medical device manufacturing and preventing material failures. Pathogens rapidly colonize untreated medical devices. This colonization causes severe healthcare complications and triggers product failures. To solve this engineering problem, developers alter the fundamental physics of thermoplastic polyurethanes (TPU). Development people reduce polymer surface roughness and disrupt bacterial attachment mechanisms by embedding inorganic fillers and applying precise mechanical surface modifications. These technical interventions transform standard elastomeric polyurethanes into commercially viable, highly infection-resistant medical materials. You can also read: Polyurethane Composites with Industrial Waste Fillers. Tuning Properties with Antimicrobial Fillers Engineers melt compound functional fillers directly into the polymer matrix to actively suppress bacterial colonization on commercial medical devices. Courtesy of Polyurethane-Based Composites: Effects of Antibacterial Fillers on the Physical-Mechanical Behavior of Thermoplastic Polyurethanes. Manufacturers routinely compound thermoplastic polyurethanes with specific additives such as micronized silver, titanium dioxide, and chitosan to create antibacterial plastics. However, adding these fillers fundamentally shifts the thermodynamic interactions between the rigid hard segments and flexible soft segments of the polymer chain matrix. Engineers vigorously assess these modified composites to evaluate their uniaxial tensile limits before approving them for commercial production. Sample Elastic Modulus (MPa) Maximum Stress (MPa) Elongation at Break (%) Neat TPU 26. 2 ± 1. 4 36. 4 ± 1. 6 1075 ± 44 TPU-Ag 30. 5 ± 1. 6 26. 4 ± 3. 1 975 ± 87 TPU-Chitosan 33. 9 ± 1. 5 25. 9 ± 1. 3 845 ± 21 TPU-TiO2 19....


- Published: 2026-07-16
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/advancing-pvdf-separators-for-lithium-ion-batteries-011742/
- Categories: Cast Film/Sheet, Circular Economy, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Energy Generation, Industry, Materials, PFAS, Process, Resins, Semi-Finished Products, Sustainability, Testing & Analysis, Vinyl
- Tags: Thermal Stability

PVDF separators improve lithium-ion battery safety, electrolyte uptake, and thermal stability for EV and grid energy storage.

PVDF separators improve lithium-ion battery safety, electrolyte uptake, and thermal stability for EV and grid energy storage. Current commercial lithium-ion batteries rely heavily on polyethylene and polypropylene separators, which shrink at elevated temperatures, triggering catastrophic short circuits. To solve this thermal vulnerability, materials engineers developed advanced polyvinylidene fluoride (PVDF) separators. These PVDF-based architectures employ unique core-shell nanofiber networks and tightly controlled thermodynamic processing to resist heat, enhance electrolyte absorption, and prevent dendrite penetration. You can also read: Polymeric Interface Enhances Lithium-Batteries Efficiency. Electrospun Core-Shell Nanofiber Networks Manufacturers constantly balance battery energy density with thermal safety. Commercial polyolefin separators fail because they physically deteriorate under extreme operational heat. By replacing standard membranes with electrospun core-shell nanofibers, developers achieve unprecedented thermal stability. Researchers engineered a fibrous matrix using polyacrylonitrile (PAN) as the rigid core and poly (vinylidene fluoride-hexafluoropropylene) (PVDF-HFP) as the flexible shell. The PAN core acts as an unyielding structural backbone, while the PVDF-HFP shell facilitates rapid ion transport. The thermal stability tests of the commercial Celgard2400 separator, PVDF-HFP, and PAN@PVDF-HFP fiber network. Courtesy of Electrospun Core-Shell Nanofiber as Separator for Lithium-Ion Batteries with High Performance and Improved Safety. This coaxial electrospinning technique delivers a porous separator that survives volatile environments exceeding 250 °C without shrinking. For commercial applications, electric vehicle manufacturers can safely design higher-capacity battery packs without compounding the risk of thermal runaway. These robust separators also efficiently trap liquid electrolytes. This absorption capability directly accelerates fast-charge cycles and extends the overall usable lifespan of the energy storage system....


- Published: 2026-07-15
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/quantum-pigments-bring-programmable-light-to-plastics-011710/
- Categories: 3D Printing/Additive Manufacturing, Additives & Colorants, Aerospace, Automotive & Transportation, Business, Compounding, Decorating & Coatings, Design, Education & Training, Electrical & Electronics, Industry, Injection Molding, Materials, Packaging, Process, Resins, Sports & Recreation, Trending, Wearables

Quantum pigments use quantum dots to create purer, brighter, and programmable color effects in plastics, coatings, and masterbatches.

Quantum pigments use quantum dots to create purer, brighter, and programmable color effects in plastics, coatings, and masterbatches. Quantum dots have long attracted attention in electronics, displays, and advanced optics; however, Quantum Light is extending their value into coatings, plastics, masterbatches, and engineered industrial surfaces. The company develops quantum pigments that move beyond passive color reflection by capturing light, converting it, and emitting highly controlled optical responses. You can also read: Color Coordinates. Olga Alexopoulou, CEO of Quantum Light, describes this development as the emergence of a new pigment class. While conventional pigments rely on chemical processes to generate color, quantum pigments derive their optical behavior from quantum confinement in nanocrystals. As a result, manufacturers can control color purity, brightness, and spectral behavior with a level of precision that traditional pigment systems cannot deliver. A New Class of Pigments Conventional pigments primarily reflect incident light; by contrast, quantum pigments absorb light and re-emit it as highly pure color. According to Alexopoulou, these materials can produce “laser narrow” emissions, allowing manufacturers to achieve cleaner, more saturated, and more tightly controlled optical outputs. This spectral control extends across both visible and non-visible wavelengths. Consequently, Quantum Light can tune emissions to specific nanometer ranges, enabling surfaces that combine aesthetic value with functional optical performance. In practice, a plastic component could present a distinctive color to the human eye while also carrying optical information for sensors, robots, or autonomous vehicles. Where Quantum Pigments Fit A quantum pigment dispersion emits a saturated red response, highlighting...


- Published: 2026-07-14
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/ai-models-predict-polymer-degradation-during-extrusion-011703/
- Categories: 3D Printing/Additive Manufacturing, Artificial Intelligence, Building & Construction, Design, Editor's Choice Technical Paper, Elastomers, Electrical & Electronics, Equipment, Extrusion, Industry, Industry 4.0, Materials, Medical, Mixing & Blending, Process, Resins, Sensors, Software, Sustainability, Thermoplastics, Thermosets, Trending
- Tags: polymer degradation, polymer processing

Engineers use machine learning algorithms to map polymer degradation, replacing physical trials with precise predictive models for industrial extrusion pipelines.

Engineers use machine learning algorithms to map polymer degradation, replacing physical trials with precise predictive models for industrial extrusion pipelines. Manufacturers constantly battle thermal, mechanical, and hydrolytic degradation during commercial polymer processing. Heat and shear stress cause chain scission, rapidly reducing molecular weight and altering critical properties like yield stress. To overcome unpredictable variations, engineers deploy machine learning algorithms that successfully map complex thermomechanical relationships. By linking microscopic structural changes directly to macroscopic production parameters, facilities optimize manufacturing lines. You can also read: Leveraging AI to Speed Product Design Simulations. Decoding Polymer Degradation with Algorithms Instead of treating industrial extrusion lines as opaque black boxes, material scientists utilize Near-Infrared spectroscopy paired with Recursive Feature Elimination (RFE) to continuously monitor structural shifts. Feature selection isolates the specific chemical indicators that drive quality degradation. Specific wave numbers detect subtle bending and stretching, capturing real-time changes within polylactic acid chains. When developers process moisture-sensitive medical-grade polylactic acid in a nitrogen atmosphere, they require absolute control to ensure proper bioresorption of the tissue scaffold. In opposition, when fabricating packaging-grade polylactic acid (PLA) under ambient conditions, these algorithms pinpoint precisely how the melt temperature at the extruder die exit directly degrades product strength. This intelligence provides production teams with actionable data, allowing operators to dynamically adjust heating zones before manufacturing out-of-spec products. Schematic representation of the RFE process. Courtesy of Interpretable Machine Learning Methods for Monitoring Polymer Degradation in Extrusion of Polylactic Acid. Quantifying Predictive Accuracy Across Platforms Engineers quantify predictive accuracy by comparing digital...


- Published: 2026-07-13
- Modified: 2026-07-13
- URL: https://www.plasticsengineering.org/2026/07/why-communication-is-becoming-a-core-engineering-skill-011964/
- Categories: Business, Education & Training, Industry, Strategy

A newly released State of Technical Communication report reveals that the ability to communicate technical information clearly is becoming a key driver of engineering performance, innovation, and leadership.

Study analyzes nearly one million words from 200 engineering leaders, founders, and STEM professionals. As engineering projects become more complex, cross-functional, and fast-moving, technical expertise alone is no longer enough. A newly released State of Technical Communication report shows that communication is increasingly a key driver of engineering performance, innovation, and leadership effectiveness. The report synthesizes insights from approximately 200 Teach the Geek podcast transcripts, totaling nearly one million words of qualitative data. Researchers used pattern recognition, thematic clustering, narrative analysis, cross-interview comparison, and recurrence frequency estimation to identify common experiences and communication challenges described by engineers, technical leaders, founders, and STEM professionals. What the Research Found One conclusion appeared repeatedly across interviews: Technical expertise enables engineers to solve problems, but communication skills determine whether those solutions influence decisions, gain organizational support, and create measurable business impact. Communication Maturity Model for Technical Professionals. Courtesy of Teach the Geek. Participants across industries and career stages described many of the same challenges: Explaining complex technical concepts to nontechnical audiences Presenting recommendations to executives Aligning cross-functional teams Leading through organizational change Communicating confidently in high-visibility situations Why This Matters for Plastics Engineers For plastics engineers, these findings are especially relevant. Whether introducing a new polymer, defending a material selection, presenting test data, implementing process improvements, or leading sustainability initiatives, success often depends on how effectively technical information is communicated to colleagues, customers, suppliers, and decision-makers. In many organizations, engineers who can clearly connect material performance, processing data, cost implications, and business objectives are...


- Published: 2026-07-13
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/balancing-fire-resistance-and-transparency-in-pet-011760/
- Categories: Additives & Colorants, Aerospace, Automotive & Transportation, Building & Construction, Business, Compounding, Durables, Industry, Materials, People, PET, Process, Regulation, Resins, Trending

Halogen-free flame retardants improve PET fire performance while preserving transparency for electronics, solar panels, and screens.

Halogen-free flame retardants improve PET fire performance while preserving transparency for electronics, solar panels, and screens. PET shows potential for use in applications such as flexible housing for electronic devices. These include Building-Integrated Photovoltaics (BIPVs) and screens, which benefit from PET’s transparency. Currently, poor fire behavior limits its use in these areas, and most research on improving PET’s performance focuses on textiles. Increasing PET’s fire performance without sacrificing transparency is crucial for expanding its use to these applications. You can also read: Golden Design Rules: Enhancing PET Recycling Through Design. Commercial Flame Retardants for Transparent PET In a recent study, researchers investigated PET’s performance and transparency when incorporating commercial, phosphorus-based, halogen-free flame retardants. This study aimed to further research the interactions between flame retardants and PET outside the textile sector. By improving PET’s fire behavior while maintaining transparency, manufacturers can find novel uses for this polymer. To measure the heat release rate of the samples during combustion, they conducted a cone calorimeter test. By simulating real fire scenarios, this test enables characterization of a material’s burning performance. Additionally, they performed thermogravimetric analysis (TGA) to analyze the thermal stability of the samples. As a reference for the electrical and electronic sector, researchers measured flammability using the UL-94 vertical burning test. Samples of neat PET and PET with four commercially available flame retardants underwent cone calorimeter testing. Figure courtesy of A Study on Phosphorous-Based Flame Retardants for Transparent PET Composites: Fire, Mechanical, and Optical Performance. Transparency Effects of Commercial Flame Retardants To...


- Published: 2026-07-10
- Modified: 2026-07-06
- URL: https://www.plasticsengineering.org/2026/07/4d-printed-peek-powers-self-deploying-space-structures-011687/
- Categories: 3D Printing/Additive Manufacturing, Aerospace, Building & Construction, Design, Editor's Choice Technical Paper, Elastomers, Industry, Materials, People, Process, Sustainability, Thermoplastics, Trending

4D-printed shape-memory PEEK replaces heavy mechanical hinges, enabling lightweight, self-deploying smart structures for next-gen space applications.

4D-printed shape-memory PEEK replaces heavy mechanical hinges, enabling lightweight, self-deploying smart structures for next-gen space applications. Aerospace engineers constantly contend with extreme mass constraints and mechanical complexity when designing deployable orbital structures such as solar arrays and communication antennas. Traditional mechanical hinges introduce heavy, failure-prone moving parts that threaten mission viability. To address this critical bottleneck, developers now use 4D-printed shape-memory polymers (SMPs). These advanced materials leverage thermomechanical phase transitions to enable self-deployment, eliminating the need for rigid motors and significantly reducing overall launch weight. You can also read: Aerospace Plastics Market: Lighter, Stronger, and Poised for Takeoff The Physics of PEEK Actuation Material scientists focus heavily on Polyetheretherketone (PEEK) for extraterrestrial applications. PEEK delivers exceptional thermal stability, high radiation resistance, and robust mechanical strength. Engineers program the polymer by heating the material above its glass transition temperature, deforming it into a temporary, compact storage shape, and rapidly cooling it to lock the microscopic structure in place. Four-dimensional printing and test method of shape memory PEEK. (a) The equipment and construction of 4D printing. (b) The process of 4D printing PEEK composites. (c) The printed composite sample and sizes. (d) The measurement method and definition of an angle. θF was the fixed angle, and θR was the recovered angle between the horizontal line and the free side of the sample. (e) The test method and devices for the recovery force. Courtesy of The Shape Memory Properties and Actuation Performances of 4D Printing Poly (Ether-Ether-Ketone). This process vitrifies the polymer chains...


- Published: 2026-07-09
- Modified: 2026-06-30
- URL: https://www.plasticsengineering.org/2026/07/waste-coffee-grounds-as-an-additive-for-flame-retardant-films-011393/
- Categories: Bioplastics, Circular Economy, Durables, Education & Training, Film, Industry, Materials, Process, Recycling, Regulation, Resins, Sustainability, Thermoplastics, Trending

As an additive in polylactide (PLA) biocomposite films, spent coffee grounds (SCG) can improve flexibility and toughness while preventing combustion.

As an additive in polylactide (PLA) biocomposite films, spent coffee grounds (SCG) can improve flexibility and toughness while preventing combustion. Bio-Based Additives for Sustainable and Effective Flame Retardants PLA is a widely used bioplastic, but it is brittle, flammable, has low crystallinity, and has a slow crystallization rate. Plasticizers that serve as multifunctional additives can enhance PLA’s toughness while addressing these limitations. Increasing PLA’s flame retardancy is a critical area of research, as it is highly flammable. Primarily composed of lignocellulosic materials, bio-based additives can enhance flame inhibition, suppress melt dripping, and promote self-extinguishing behavior in PLA. You can also read: Upcycling Coffee Grounds: A Packaging Alternative. Spent Coffee Grounds as a Flame Retardant One source for bio-based additives is SCGs. SCGs, the solid waste generated during coffee brewing, are a major byproduct of the coffee industry. When used as biodegradable additives or fillers, this material can enhance mechanical properties and reduce production costs for polymer composites. Additionally, they can interact with flame retardants to form intumescent flame retardant (IFR) systems, improving the flame retardancy of PLA. Coffee oil, found in SCGs, also acts as a natural plasticizer, further increasing toughness and reducing brittleness of PLA composites. A recent study explored how SCGs, in tandem with phosphate-based plasticizers, enhance the mechanical properties and heat resistance of PLA. Researchers developed biocomposite films with added plasticizers and SCGs. Figure courtesy of Upcycling spent coffee grounds as a sustainable additive for superior impact-resistant and flame-retardant polylactide biocomposite films. Effect of Plasticizer Researchers produced...


- Published: 2026-07-08
- Modified: 2026-07-08
- URL: https://www.plasticsengineering.org/2026/07/why-recycled-plastics-face-limits-in-building-products-011720/
- Categories: Building & Construction, Composites, Compounding, Decorating & Coatings, Education & Training, Industry, Materials, People, PFAS, Process, Recyclate, Recycling, Recycling, Regulation, Resins, Semi-Finished Products, Sustainability, Testing & Analysis, Thermoplastics, Trending
- Tags: Dimensional Stability, Flame Retardants

Recycled plastics can expand in building products only when circularity meets the same requirements that govern conventional construction materials.

Recycled plastics can expand in building products only when circularity meets the same requirements that govern conventional construction materials. Construction offers a large outlet for recycled plastics because the sector already uses polymer-based products with long service lives. Roofing membranes, siding, decking, pipes, sealants, drainage components, and composite profiles all create routes for recycled content. Companies such as Plaswood demonstrate how recycled plastic lumber can be used in construction and infrastructure applications. That range makes direct substitution difficult. Recycled polymers cannot qualify only because they contain post-consumer or post-industrial content. The compound must meet mechanical, fire, weathering, chemical, and dimensional requirements. It must also retain those properties after processing, installation, and exposure without compromising code compliance or service life. You can also read: Sorting Construction Waste in Real Time. Fire Performance Sets the First Limit Cone calorimetry measures reaction-to-fire behavior in polymer materials, including ignition time, heat release rate, smoke production, and mass loss under controlled radiant heat exposure. Courtesy of Motis. Fire performance often represents the first qualification barrier for recycled plastics in building products. A recycled PP or PE compound may meet tensile, flexural, or impact targets. However, it may still fail flame-spread, smoke-density, or heat-release requirements. The main limitation comes from batch-to-batch variability. Filler level, pigment chemistry, stabilizer depletion, moisture content, and thermal history can all influence ignition response, melt dripping, smoke formation, and heat release. Fire testing evaluates the finished article rather than the polymer grade alone. A component responds to flame exposure according to its...


- Published: 2026-07-07
- Modified: 2026-07-07
- URL: https://www.plasticsengineering.org/2026/07/3d-printed-artificial-muscles-advance-soft-robotics-011680/
- Categories: 3D Printing/Additive Manufacturing, Artificial Intelligence, Design, Editor's Choice Technical Paper, Education & Training, Hydrogels, Industry, Materials, Medical, People, Process, Thermoplastics, Trending, Vinyl
- Tags: Soft Robotics

Engineers automate the manufacturing of artificial muscles by printing electroactive PVC gels and thermomechanical shape-memory polymers.

Engineers automate the manufacturing of artificial muscles by printing electroactive PVC gels and thermomechanical shape-memory polymers. Traditional manufacturing restricts soft robotic developers to simple, rigid motor assemblies and labor-intensive manual casting methods. To eliminate these industrial bottlenecks, materials scientists engineer dynamic polymer artificial muscles that utilize applied electromechanical Maxwell forces and thermomechanical entropic recovery. These advanced materials directly replace conventional hardware, enabling manufacturers to build highly flexible, autonomous actuation systems. You can also read: Soft Robotics in Medicine: A Growing Trend Powered by Hydrogels. Driving Actuation Through Maxwell Forces Engineers targeted electric fields to drive the cyclical actuation of polyvinyl chloride (PVC) gel artificial muscles. When controllers apply an electrical field ranging from 400 to 800 V, PVC molecules migrate rapidly toward the anode. This molecular migration polarizes the internal gel network and generates a robust Maxwell force. This specific electromechanical interaction induces precise creep deformation near the anode, alongside massive structural compression throughout the material thickness. Once operators deactivate the electric field, the inherent elasticity of the PVC network forces the muscle back into its original resting shape. To achieve these properties, chemists formulate the active gel by mixing PVC, dibutyl adipate plasticizer, and tetrahydrofuran solvent at a precise 1:7:12 mass ratio. Deformation principle of the PVC-gel actuator. (a) Discharge (b) Charge. Courtesy of Direct Writing Corrugated PVC Gel Artificial Muscle via Multi-Material Printing Processes. Designing Shape-Memory Polymer Muscles On the contrary, developers design shape-memory polymers (SMPs) to function as programmable artificial muscles utilizing entropic recovery. Material scientists engineer...


- Published: 2026-07-06
- Modified: 2026-06-30
- URL: https://www.plasticsengineering.org/2026/07/robotic-ultrasonic-welding-scales-fuselage-assembly-011672/
- Categories: Adhesives, Aerospace, Business, Composites, Design, Editor's Choice Technical Paper, Education & Training, Equipment, Industry, Materials, Process, Resins, Thermosets, Trending, Welding

Engineers leverage ultrasonic welding to assemble full-scale thermoplastic fuselages, eliminating mechanical fasteners and cutting cycle times.

Engineers leverage ultrasonic welding to assemble full-scale thermoplastic fuselages, eliminating mechanical fasteners and cutting cycle times. Aerospace engineers face massive bottlenecks when utilizing traditional mechanical fasteners to assemble large-scale aircraft structures. To solve this problem, manufacturers leverage robotic sequential ultrasonic welding. This innovative process converts high-frequency, low-amplitude mechanical vibrations from a specialized sonotrode into intense, localized heat. The system focuses on frictional heating at the interfaces and viscoelastic heating directly within the composite matrix. By precisely directing this thermal energy, aerospace technicians permanently fuse structural thermoplastic composites without a single rivet. You can also read: Welding Wood-Plastic Composites. Precise Heat Control Engineers control this rapid heating using a specialized feature called an energy director. Designers mold these discrete geometric protrusions directly onto the mating surfaces of the composite parts. Manufacturers frequently utilize 0. 2 mm-high triangular ridges possessing a 90º apex. The energy director intentionally features a lower stiffness than the surrounding bulk composite structure. When the robotic sonotrode applies its 20 kHz frequency and exactly 65. 8-micrometer peak-to-peak amplitude vibrations, this localized lower stiffness forces the energy director to undergo an increased cyclic strain. This targeted strain concentrates all heat generation exactly at the weld interface. The thermal energy rapidly melts the thermoplastic, facilitating deep molecular bonding before the surrounding composite matrix degrades. This precise thermal control allows aerospace manufacturers to ensure repeatable bonds across massive structural components. Longitudinal cross-section micrograph of a SF CF/LMPAEK coupon. The triangular ridges molded during panel production (visible at the top of the...


- Published: 2026-07-03
- Modified: 2026-06-30
- URL: https://www.plasticsengineering.org/2026/07/regulation-is-reshaping-investment-decisions-in-plastics-011550/
- Categories: Circular Economy, Design, Education & Training, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, People, Process, Recycling, Recycling, Regulation, Sustainability

Regulation is reshaping plastics investment by compressing decision cycles, raising compliance costs, and redirecting capital across the value chain.

Regulation is reshaping plastics investment by compressing decision cycles, raising compliance costs, and redirecting capital across the value chain. Plastics companies used to time investments around demand cycles and return targets. Now they time them to coincide with compliance deadlines. That shift is structural and accelerating globally. You can also read: The Regulatory Blind Spot in Plastic Design. The Policy Clock Replaces the Market Cycle Recycled content mandates, extended producer responsibility schemes, and plastic taxes are reordering capital priorities across the entire value chain. The EU's Packaging and Packaging Waste Regulation PPWR 2025/40 entered into force in February 2025. It takes effect in August 2026 and mandates that all packaging on the EU market be recyclable by 2030. By that same date, plastic packaging must meet recycled content thresholds. According to the European Commission, these range from 30% to 65%, depending on the category. These are binding legal deadlines with enforcement consequences, not aspirational goals. Companies now align capital expenditure directly with regulatory timelines. Investment decisions that once followed return cycles now follow policy calendars. Flexibility shrinks. Risk concentrates. But early movers gain durable competitive positions over those who wait. Compliance Costs Reshape the Capital Stack The EPR cycle places end-of-life responsibility squarely on producers. Fees, recyclability grades, and compliance costs now flow back through every stage of the packaging value chain. Courtesy of Paramount Global. Regulation does not only change timelines. It rewrites cost structures across the board. EPR fees create direct financial pressure. Belgium currently charges up to...


- Published: 2026-07-02
- Modified: 2026-06-30
- URL: https://www.plasticsengineering.org/2026/07/material-substitution-in-polymers-from-resin-price-to-system-cost-011533/
- Categories: Business, Industry, Materials, People, Regulation, Resins, Results, Strategy, Sustainability, Thermoplastics, Trending

Material substitution in polymer engineering now depends on total system cost, linking processability, performance, and lifecycle economics.

Material substitution in polymer engineering now depends on total system cost, linking processability, performance, and lifecycle economics. From Price per Kilogram to Cost per Function Material selection no longer starts with resin price. Engineers now focus on total system cost. According to the International Organization for Standardization, lifecycle assessment frameworks require companies to include environmental and operational impacts in material decisions. Carbon footprint and durability now influence material choice. You can also read: What is Ecomodulation? Boosting Extended Producer Responsibility. Simple price comparisons can mislead. Lower-cost resins may increase tooling needs, slow production, and raise defect rates. Engineers, therefore, measure cost per function. They assess how a material performs within the full system. This approach favors polymers that improve reliability and simplify manufacturing. It also reduces long-term risk. Lifecycle assessment frameworks show that material selection depends on total system cost, including production, use, and end-of-life impacts. Courtesy of Opportunities and Challenges in the Application of Bioplastics: Perspectives from Formulation, Processing, and Performance. Processability as a Hidden Profit Driver Processing performance directly shapes production costs. Faster cycle times increase output and lower cost per part. Data from the Journal of Applied Polymer Science show that flow and thermal behavior affect molding efficiency. Better flow reduces defects and scrap. BASF patents demonstrate how material design enhances processing performance, as high-flow polyamides improve mold filling and dimensional stability, helping reduce defects such as warpage. Manufacturers now prefer materials that are easier to process. Lower viscosity and wider processing windows support more stable operations....


- Published: 2026-07-01
- Modified: 2026-06-30
- URL: https://www.plasticsengineering.org/2026/07/what-is-shrinkage-in-injection-molding-011519/
- Categories: Aerospace, Automotive & Transportation, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Industry, Injection Molding, Materials, Medical, Process, Resins, Thermoplastics

Shrinkage is a natural result of cooling and solidification in injection molding, but material structure and process conditions strongly affect its magnitude.

Shrinkage is a natural result of cooling and solidification in injection molding, but material structure and process conditions strongly affect its magnitude. Key Points: Shrinkage is a natural effect of cooling in injection molding. Semi-crystalline polymers usually shrink more than amorphous ones. Pressure, cooling, and fiber orientation affect final dimensions. Better process control helps reduce shrinkage variation. Shrinkage is a natural part of injection molding. It affects part dimensional stability and, if not understood correctly, can cause delivery problems and high added costs. This article reviews why shrinkage occurs and how both material selection and process conditions affect it. You can also read: Read Your Material Datasheet to Cut Molding Costs and Defects. Shrinkage refers to the dimensional contraction of an injection-molded part. It is a completely natural phenomenon in injection molding. Every molder must deal with dimensional change in molded components, and only accurate prediction can ensure that a part performs as intended. When a plastic is above its glass transition temperature and enters the mold, its molecules have high energy and therefore greater intermolecular spacing. The free space between molecules, often called free volume, increases as temperature rises. As the molded part transfers heat to the mold, it cools and solidifies. Consequently, the free volume decreases. That reduction appears as a reduction in part size. A part measured immediately after molding can be up to 2% larger in every dimension than the same part after it has fully cooled and reached its final shape, which may take roughly...


- Published: 2026-06-30
- Modified: 2026-06-18
- URL: https://www.plasticsengineering.org/2026/06/eco-hybrids-vs-foam-cores-in-aerospace-011508/
- Categories: Aerospace, Composites, Education & Training, Foam Processing, Foaming Agents, Industry, Materials, Process, Resins, Thermoplastics, Thermosets, Trending

Engineers benchmark flax-glass progressive folding against carbon-Kevlar foam cores to optimize kinetic energy absorption for aircraft safety.

Engineers benchmark flax-glass progressive folding against carbon-Kevlar foam cores to optimize kinetic energy absorption for aircraft safety. Aviation engineers must absorb catastrophic kinetic energy while strictly minimizing aircraft weight to reduce operational fuel costs. Traditional metallic components deliver vital safety but impose massive weight penalties. To solve this commercial challenge, materials scientists currently contrast two distinct aerospace energy-absorption philosophies: progressive folding in natural-synthetic open-web profiles versus core crushing in synthetic closed foam panels. You can also read: Pros and Cons of Natural Fiber-Reinforced Plastics in Automotive. Progressive Folding in Open-Web Profiles Engineers utilize flax and E-glass eco-hybrid composites to manage quasi-static axial crushing. During severe deceleration, these open-web profiles dissipate energy through a progressive folding mechanism. The structures undergo controlled buckling, localized fragmentation, and fiber splaying. High transverse shear stresses drive interlaminar cracks, allowing the composite to yield safely over an extended period. The crushing morphology at each stage of crushing (I: Zone I) (II: Zone II) (III: Zone III). Courtesy of Experimental Investigation of the Axial Crushing Response of Flax/Glass Eco-Hybrid Self-Supporting Web Composites. To prevent catastrophic brittle failure, designers place natural flax fibers on the exterior layers. These flax fibers possess a tensile strength of 370 to 630 MPa and physically hold the shattered internal E-glass layers together. By alternating natural and synthetic layers in an intercalated stacking sequence, manufacturers minimize the formation of destructive interlaminar cracks. This specific intercalated configuration achieves a highly competitive specific energy absorption of 20. 36 kJ/kg and a crash force efficiency exceeding...


- Published: 2026-06-29
- Modified: 2026-06-18
- URL: https://www.plasticsengineering.org/2026/06/polymer-concrete-drives-zero-waste-modular-construction-011503/
- Categories: Additives & Colorants, Building & Construction, Business, Circular Economy, Composites, Editor's Choice Technical Paper, Extrusion, Industry, Materials, People, Process, Recycling, Recycling, Resins, Results, Sustainability, Thermoplastics, Thermosets, Trending

Engineers eliminate calcination emissions by encapsulating waste inside cross-linked polymers, creating load-bearing, modular blocks for rapid deployment.

Engineers eliminate calcination emissions by encapsulating waste inside cross-linked polymers, creating load-bearing, modular blocks for rapid deployment. The construction industry battles massive carbon emissions from Portland cement calcination and fragile structures. To solve this crisis, materials engineers replace reactive cement with highly cross-linked polymer networks. These advanced matrices physically encapsulate raw construction waste, forming exceptionally durable polymer concrete structures. By eliminating internal hydration voids entirely, developers establish a new paradigm for sustainable, high-strength industrial architecture. You can also read: Reinforcing Concrete With Mixed Plastics Waste. Engineering the Matrix Interface Transition from ordinary concrete to polymer concrete. Courtesy of Review of Component Materials and Diverse Applications of Polymer Concrete. Standard organic polymer matrices inherently reject highly porous, variable-textured aggregate particles such as crushed brick or recycled waste glass. As a result, formulators rely on physical encapsulation rather than chemical reactivity to create resilient composite materials. To achieve this, technicians apply precise silane coupling agents, specifically 3-methacryloxypropyl trimethoxy silane, to improve wetting of the aggregate particles. In turn, this pretreatment transforms the interfacial transition zone and significantly improves water resistance and chemical stability. At the same time, formulators carefully pair specific silanes with corresponding resins, using Dynasil DEMO for polyester mixtures and Dynasil AMEO for epoxies. By also replacing fine aggregates with seven to twenty-five percent waste glass, manufacturers optimize density and ensure that hydrophobic polymer particles effectively wrap the aggregates. Consequently, these targeted combinations lock waste materials securely within the matrix and permanently block microvoids. Comparative Performance Metrics To evaluate commercial...


- Published: 2026-06-26
- Modified: 2026-06-17
- URL: https://www.plasticsengineering.org/2026/06/reusable-packaging-fatigue-washing-and-surface-damage-011499/
- Categories: Business, Circular Economy, Design, Durables, Education & Training, Industry, Materials, Microplastics, Packaging, People, PET, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Resins, Results, Sustainability, Thermoplastics, Trending

Repeated washing, handling, and abrasion can damage reusable plastic packaging, reducing durability, cleanability, and practical service life.

Repeated washing, handling, and abrasion can damage reusable plastic packaging, reducing durability, cleanability, and practical service life. Key Points: Reusable packaging faces new durability demands: As reusable packaging adoption grows under Europe’s PPWR regulations, materials must withstand repeated cycles of impact, stacking, abrasion, washing, and sanitization without losing performance. Surface damage can shorten package life: Scratches, stress concentrators, and fatigue-related microcracks in materials like PP and HDPE can accumulate over time, leading to structural degradation long before visible failure occurs. Cleanability is as important as durability: Worn and scratched surfaces can trap food residues and microorganisms, creating hygiene risks that may determine end-of-life for reusable packaging before the package actually breaks. Regulation Pushes Reuse, But Physics Sets the Limit Reusable packaging now operates within a more demanding regulatory framework. In Europe, the Packaging and Packaging Waste Regulation entered into force on February 11, 2025, and will generally take effect on August 12, 2026. That policy shift will place a larger number of trays, totes, and food-contact containers into repeated service cycles across distribution and recovery systems. However, regulatory targets do not alter the underlying response of polymers to mechanical, thermal, and chemical stress. They simply make those limitations more visible under extended use conditions. A reusable package must withstand a demanding service history. That history includes stacking loads, impact events, flexural deformation, conveyor-induced abrasion, hot washing, alkaline cleaning agents, sanitizing treatments, and drying. Any individual cycle may appear relatively mild. The degradation process emerges through cumulative exposure and progressive damage...


- Published: 2026-06-25
- Modified: 2026-06-17
- URL: https://www.plasticsengineering.org/2026/06/how-plastics-shaped-phones-from-bakelite-to-smartphones-011419/
- Categories: Business, Decorating & Coatings, Design, Education & Training, Electrical & Electronics, Industry, Injection Molding, Materials, People, Polyethylene, Polyolefins, Polypropylene, Process, Resins, Semi-Finished Products, Silicones, Sustainability, Thermoplastics, Trending, Wire & Cable

Plastics helped transform phones from bulky early telephones into lighter, more durable, and higher-performing mobile devices.

Plastics helped transform phones from bulky early telephones into lighter, more durable, and higher-performing mobile devices. In March 1876, Alexander Graham Bell successfully received U. S. patent 174,465 for the telephone. Early phones bore little resemblance to the sleek devices we know now. An early assembled telephone contained mouthpieces of varying sizes, bulky drum-like diaphragms, and wires connecting a liquid transmitter to vibrating needles to transmit sound. With the help of plastics, phone technology evolved from simple sound-transmitting devices into handheld computers capable of connecting the world. You can also read: Apple’s New iPhone Packaging: A Sustainable Shift? Evolution of Phone Materials This year marks the one-hundred-and-fifty-year anniversary of the revolutionary patent. Since the telephone’s invention, its inner and outer components were primarily made of wood, iron, brass, and mica. Today’s phones contain vastly different components assembled from engineered thermoplastics, liquid crystals, and polymeric adhesives. This transformed phones into everyday essentials and, ultimately, pocket-sized computers. As electronics evolved, polymeric materials supporting phone technology did too. In turn, this major transition helped shift wood and metal components to miniaturized processors, sensors, and antennas. With smaller device footprints and increasingly portable connectivity, phones now require new materials to keep pace with the technological shift. Home and Pay Phones The largest shift in phone materials came during the late 1920s and early 30s with the use of Bakelite. As a result, Bakelite, made of phenol and formaldehyde, replaced traditional outer metal casings, transforming phones into lighter and more aesthetic constructions. This reduced production...


- Published: 2026-06-24
- Modified: 2026-06-17
- URL: https://www.plasticsengineering.org/2026/06/chemical-recyclings-future-depends-on-legal-classification-011493/
- Categories: Editor's Choice Technical Paper, Energy Generation, Industry, Legal Analysis, Materials, Process, Recyclate, Recycling, Regulation, Sustainability
- Tags: Advanced Recycling, Chemical Recycling, polymer processing, pyrolysis, Waste Management

The future of advanced recycling may depend as much on regulatory classification as on reactor design.

The future of advanced recycling may depend as much on regulatory classification as on reactor design. Key Points: Regulation may be the biggest hurdle: The future of advanced recycling depends not only on process performance but also on whether facilities are legally classified as manufacturing plants or waste-management operations. Classification drives project economics: Manufacturing status can simplify permitting, siting, and financing, while waste or incineration classifications may trigger stricter regulations, higher costs, and greater community opposition. State and federal policies remain divided: Many states now classify advanced recycling as manufacturing, but ongoing EPA debates over pyrolysis regulation could significantly impact permitting requirements, emissions oversight, and industry growth. Advanced recycling has reached a point where process and regulatory engineering work in tandem. Companies still have to manage the familiar technical constraints: feedstock heterogeneity, halogen contamination, catalyst fouling, wax formation, residue handling, and product upgrading. But once a project moves beyond pilot scale, another constraint starts to dominate. The key question often shifts from conversion efficiency to legal classification. For many developers, the issue no longer centers on whether pyrolysis, gasification, or depolymerization can generate a usable product slate. It centers on whether the law treats the facility as a manufacturing facility or as a waste management facility. That distinction directly affects commercialization. A manufacturing classification usually places a plant within an industrial permitting framework. A waste-management or incineration classification can trigger stricter emissions controls, more difficult siting, longer review, and stronger local opposition. Those differences can alter project economics as much...


- Published: 2026-06-23
- Modified: 2026-06-17
- URL: https://www.plasticsengineering.org/2026/06/bithiazole-based-polymers-for-scalable-solar-hydrogen-011481/
- Categories: Decorating & Coatings, Editor's Choice Technical Paper, Education & Training, Energy Generation, Industry, Materials, People, Process, Sustainability

Bithiazole-based polymers improve solar hydrogen production by linking backbone design, nanoparticle processing, and interfacial engineering.

Bithiazole-based polymers improve solar hydrogen production by linking backbone design, nanoparticle processing, and interfacial engineering. Polymer Photocatalysts Target Scalable Hydrogen Production As industries move toward cleaner energy, solar-driven hydrogen offers a direct route to decarbonization. Many current systems still depend on fossil fuels or energy-intensive electrolysis, which keeps costs and emissions high. Polymer-based photocatalysts offer an alternative approach to decentralized fuel generation. Because these materials can be processed from solution, they are compatible with established manufacturing methods such as coating, dispersion processing, and colloidal formulation. That compatibility could enable lightweight, large-area, low-cost hydrogen-generating surfaces that fit within existing plastics manufacturing infrastructure. New Building Blocks Enable Performance Gains Optical absorption and energy level analysis of PFOTz and PFOTzT polymers. PFOTzT exhibits red-shifted absorption and a stabilized LUMO, reflecting enhanced conjugation and improved electronic structure. Courtesy of Designing bithiazole-based conjugated polymers as alternatives to benzothiadiazoles for photocatalytic hydrogen evolution. Most high-performing systems still rely on benzothiadiazole (BT) backbones, which limits design flexibility. Recent research introduces bithiazole (Tz) as an alternative electron-deficient unit for conjugated polymer photocatalysts. The goal was to determine whether replacing conventional building blocks could improve hydrogen production while preserving compatibility with solution processing. Researchers developed two polymers, PFOTz and PFOTzT. In the PFOTzT variant, they inserted a thiophene spacer that improved backbone planarity. In organic electronics, a flatter backbone improves π–π stacking, thereby extending conjugation, increasing light absorption, and stabilizing charge transport without altering the required processing routes. Nanoparticle Processing Aligns with Industrial Methods One of the most relevant...


- Published: 2026-06-22
- Modified: 2026-07-01
- URL: https://www.plasticsengineering.org/2026/06/biodegradability-understanding-what-breaks-down-and-what-doesnt-010124/
- Categories: Bioplastics, Circular Economy, Editor's Choice Technical Paper, Education & Training, Flexible Packaging, Food Packaging, Industry, Materials, Microplastics, Packaging, People, Process, Recycling, Recycling, Regulation, Sustainability, Trending

Microorganisms metabolize polymer carbon into CO₂ or CH₄, proving actual biodegradation beyond physical or chemical degradation.

Microorganisms metabolize polymer carbon into CO₂ or CH₄, proving actual biodegradation beyond physical or chemical degradation. Misconceptions still prevail in the conversation surrounding biodegradable plastics. Many people assume that any material labeled “biodegradable” will vanish naturally within weeks or months. However, actual biodegradation depends not only on the polymer’s chemistry but also on the environmental conditions it faces. Recognizing this distinction helps designers create materials that genuinely support circularity. In their paper Dos and Don’ts When Assessing the Biodegradation of Plastics, researchers urge the industry to apply greater rigor when defining and verifying biodegradability. They emphasize that only microbial assimilation of plastic carbon can prove biodegradation, not indirect signs such as visual disintegration or mass loss. What True Biodegradation Means Microorganisms drive biodegradation by metabolizing the carbon in a polymer and converting it into CO₂ in aerobic environments or CH₄ in anaerobic systems, while also producing microbial biomass. Researchers track this process through respirometric measurements that quantify gas evolution or oxygen consumption over time, providing a direct measure of microbial activity. They also use carbon–isotope–labeled plastics to trace polymer carbon into microbial biomass. This complementary validation provides strong, quantitative evidence that microbes have incorporated carbon atoms from the plastic into living cells, rather than leaving them as fragments or oxidized residues. In contrast, changes such as weight loss, surface cracking, or reduced tensile strength reflect physical or chemical degradation, rather than biodegradation. A material may disintegrate completely without being biologically assimilated. Assessing Plastic Biodegradation Demands a Thorough Characterization of Both...


- Published: 2026-06-19
- Modified: 2026-06-11
- URL: https://www.plasticsengineering.org/2026/06/bcomp-x-ather-bio-composites-redefining-electric-two-wheelers-011438/
- Categories: Automotive & Transportation, Bioplastics, Business, Circular Economy, Composites, Design, Education & Training, Industry, Injection Molding, Materials, Process, Resins, Sustainability, Thermoforming, Trending

Redux highlights flax-based composites, redefining lightweight EV design with sustainable, high-performance materials.

Redux highlights flax-based composites, redefining lightweight EV design with sustainable, high-performance materials. As the electric mobility sector evolves, the future of mobility now extends beyond the traditional metrics of battery chemistry and drivetrain efficiency; there is also a challenge in materials. Researchers at Ather and Bcomp are revolutionizing vehicle architecture by prioritizing sustainable materials and their long-term environmental impact. You can also read: Natural Fibers are Trending for Plastic Reinforcement. A recent collaboration between Bcomp and Ather Energy offers insight into how natural fiber composite solutions can shape the future of two-wheel mobility. Their joint concept vehicle, the Redux moto-scooter, demonstrates how bio-based composites can move beyond niche applications to become central to both structural design and brand identity. From Plastics to Plant-Based Performance At the heart of Redux is ampliTexTM, a material developed by Bcomp, a woven flax-fiber composite. Unlike conventional plastics reinforced with glass or CF, this material derives from a renewable source. The company states that pairing the bio-based fabric with a thermoset matrix results in a high-performance structural material. The consequences of this development are significant. According to Bcomp, the material has a significantly lower carbon footprint than traditional materials such as ABS, glass fiber, or carbon fiber. ampliTexTM can reduce CO₂ emissions by up to 85% compared to other alternatives, while also offering viable end-of-life pathways such as energy recovery through incineration. This clearly states a shift in the role of composites, not only optimizing mechanical performance and contributing to lightweight solutions but also balancing...


- Published: 2026-06-18
- Modified: 2026-06-18
- URL: https://www.plasticsengineering.org/2026/06/how-regionalization-is-reshaping-polymer-trade-flows-011528/
- Categories: Business, Industry, Materials, People, Regulation, Resins, Results, Strategy, Sustainability, Trending

Rising costs and trade friction are splitting polymer networks: global scale remains vital for virgin resins, while circularity drives regionalism.

Rising costs and trade friction are splitting polymer networks: global scale remains vital for virgin resins, while circularity drives regionalism. Polymer supply networks still run on global trade. They have not split into self-contained regional systems. According to Houssini, Li, and Tan in Communications Earth & Environment, the plastic trade reached a vast scale in 2022. UNCTAD data cited in the research brief shows similar intensity in 2023. Those flows still connect feedstock-rich exporters, large conversion hubs, and end-use markets. You can also read: Interest Grows in Chemical Recycling. That structure reflects industrial geography, not corporate habit. The Nature analysis shows feedstocks remain concentrated in resource-rich regions, while processing clusters are in major manufacturing economies. That pattern makes full regional self-sufficiency difficult outside large blocs. Tan and co-authors also show in Circular Economy that trade shocks usually reroute flows rather than shrink them outright. Resilience Redefines Supply Chains Companies now want flexibility inside those global networks. They do not want pure efficiency at any cost. OECD analysis argues that firms increasingly add redundancy, diversify their supplier base, and screen for geopolitical exposure rather than pursue simple reshoring. The WTO’s Global Value Chain Development Report 2025 reaches a similar conclusion. It describes “reglobalization,” not deglobalization, with shorter, more diversified chains within wider global systems. Global plastics value chain flows from production to end-of-life, highlighting dominant packaging demand, material losses, and the limited share of recycling relative to landfill and incineration. Courtesy of Complexities of the global plastics supply chain revealed in...


- Published: 2026-06-18
- Modified: 2026-06-10
- URL: https://www.plasticsengineering.org/2026/06/sc-pla-nanospheres-revolutionize-smart-agrochemical-delivery-011431/
- Categories: Building & Construction, Business, Circular Economy, Education & Training, Industry, Materials, Microplastics, People, Process, Semi-Finished Products, Strategy, Sustainability, Thermoplastics, Trending

Engineers use stereo-complexed PLA nanospheres to halt pesticide waste and boost crop yields via precise, trigger-activated release kinetics.

Engineers use stereo-complexed PLA nanospheres to halt pesticide waste and boost crop yields via precise, trigger-activated release kinetics. Traditional pesticide formulations create major industrial inefficiencies. In many cases, unencapsulated chemicals wash off targets rapidly, pollute nearby environments, and waste valuable inputs. To overcome this retention problem, engineers use stereo-complexed poly(lactic acid) (SC-PLA) nanospheres. By doing so, they exploit the stereo-complexation of enantiomeric chains between poly(L-lactic acid) (PLLA) and poly(D-lactic acid) (PDLA) to create highly ordered, dense crystalline structures. As a result, these polymers protect active ingredients from premature degradation and then release their payloads only when specific environmental triggers activate the matrix. You can also read: Agro-Waste to Biopolymers: Upcycling with Bio-Additives. The Physics of Crystalline Encapsulation To build these advanced nanospheres, engineers utilize a precise emulsion process. As technicians evaporate the organic solvent dichloromethane, the physical distance between the polymer chains shortens. This forces adjacent PLLA and PDLA chains to aggregate, directly altering the polymer's morphological self-assembly. The material transforms from chaotic, petal-like structures into smooth, regular spherical or golf-ball-like shapes exhibiting massive crystallinity. Synthetic illustration showing the preparation of Avm@SC-PLA. Courtesy of Design of Multifunctional SC-PLA Pesticide Carrier System and Study of Controlled-Release Performance. Manufacturers leverage this dense matrix to create an impenetrable barrier against environmental threats. While normal photolysis degrades unprotected ingredients rapidly, the closed SC-PLA surface absorbs, scatters, and reflects ultraviolet light. Engineers effectively shield the internal pesticide, keeping the chemical payload lethal until it reaches the intended biological target. Developers also precisely control nanosphere size,...


- Published: 2026-06-17
- Modified: 2026-06-10
- URL: https://www.plasticsengineering.org/2026/06/photothermal-curing-drives-advanced-thermoset-manufacturing-011421/
- Categories: 3D Printing/Additive Manufacturing, Aerospace, Automotive & Transportation, Business, Design, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Equipment, Industry, Materials, Medical, People, Process, Resins, Results, Thermosets

Engineers utilize photothermal conversion to 3D print thermoset composites, cutting oven curing and delivering robust parts for industry.

Engineers utilize photothermal conversion to 3D print thermoset composites, cutting oven curing and delivering robust parts for industry. Traditional composite manufacturing forces engineers into costly, multi-day layups and energy-intensive oven curing cycles. Additive manufacturing solves these bottlenecks using in-situ photothermal conversion. When developers expose carbon fibers to monochromatic blue laser light, the fibers absorb electromagnetic energy and generate intense localized heat instantly. This rapid thermal spike triggers ring-opening metathesis polymerization within thermoresponsive resins, curing the matrix without external heat. To maintain strict geometric tolerances before curing, direct ink writing systems rely on engineered rheology. Formulators utilize shear-thinning and rapid elastic modulus recovery to prevent structural collapse mid-air. You can also read: Recycled PETG Powers Carbon Fiber Filaments for 3D Printing. Evaluating Mechanical and Energy Metrics Performance comparison between In-Situ Printed and Traditional cast Manufacturing Method Material Profile Tensile Strength Tensile Modulus Thermal Energy Demand In-situ Printed Continuous CF (51. 4 vol%) 1. 48 GPa 106. 7 GPa 0. 45 kJ Traditional Cast Continuous CF (51. 4 vol%) 1. 66 GPa 110. 7 GPa 6912 kJ Adapted from Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing. To evaluate industrial viability, material scientists compare printed structures directly against established baselines. Reviewing these metrics, engineers observe a highly favorable performance trade-off. While printed continuous fiber composites sacrifice a fractional amount of ultimate tensile strength compared to cast samples, they maintain highly competitive elastic moduli. The commercial advantage surfaces in profound energy reduction. Production facilities eliminate massive thermal ovens and extended...


- Published: 2026-06-16
- Modified: 2026-06-10
- URL: https://www.plasticsengineering.org/2026/06/plastic-pellet-loss-rules-turn-microplastics-into-a-plant-operations-issue-011373/
- Categories: Business, Circular Economy, Compounding, Education & Training, Industry, Materials, Microplastics, Mixing & Blending, People, Process, Recycling, Resins, Sustainability, Trending

EU pellet-loss rules make spill prevention a plant operations issue, with new demands for containment, procedures, and recordkeeping.

EU pellet-loss rules make spill prevention a plant operations issue, with new demands for containment, procedures, and recordkeeping. Plastic pellet loss now falls under Regulation (EU) 2025/2365. The regulation establishes requirements to prevent pellet loss and contain it throughout the supply chain. This shift places the issue within the scope of plant operations rather than only within the broader environmental context. It has direct implications for processors, compounders, recyclers, warehouses, terminals, and logistics providers. The regulatory focus is on pellet loss during routine handling, storage, transfer, and transport of primary plastic pellets. The key question is whether facilities maintain effective control over pellet release during receiving, conveying, packaging, clean-up, and shipment. They must also maintain the records needed to demonstrate compliance with regulatory and customer requirements. You can also read: Engineering Innovations for Microplastic Prevention and Control. Why Pellet Loss Demands Technical Attention Pellet loss typically occurs during routine handling operations rather than under major upset conditions. Typical release points include truck and rail unloading, silo charging, and pneumatic conveying. Additional release points include manual transfer, Gaylord discharge, bag rupture, purge handling, and loading dock operations. Release likelihood increases at transfer interfaces and in outdoor handling zones. The risk is greater where drains, traffic lanes, or stormwater pathways facilitate pellet migration beyond the initial release area prior to recovery. This operating profile makes pellet loss a control issue rather than an awareness issue. A site may maintain throughput and product quality while still generating repeated low-volume releases. Technically, pellet loss...


- Published: 2026-06-15
- Modified: 2026-06-10
- URL: https://www.plasticsengineering.org/2026/06/optimizing-polymeric-coating-formulations-using-ai-011408/
- Categories: Adhesives, Artificial Intelligence, Automotive & Transportation, Cast Film/Sheet, Decorating & Coatings, Editor's Choice Technical Paper, Education & Training, Film, Industry, Materials, Process, Resins, Software, Trending

Designing high-performance polymeric coatings requires balancing multiple formulation variables that interact in complex and often unpredictable ways.

Designing high-performance polymeric coatings requires balancing multiple formulation variables that interact in complex and often unpredictable ways. Polymeric coatings protect steel, concrete, and composite structures from moisture, corrosion, UV radiation, and chemical attack. They extend service life and reduce maintenance costs. However, developing a high-performance coating remains a difficult formulation problem. Researchers are using a different approach that supports more predictive formulation optimization and reduces reliance on purely iterative testing. This approach uses AI to map nonlinear relationships between formulation variables, processing conditions, and performance outcomes. Structured descriptors and experimental datasets help to derive these relationships. You can also read: Self-Healing Coatings for Automotive Applications. The Challenge of Complex Formulations Traditional coating development still depends heavily on trial-and-error formulation. Researchers adjust a composition, run tests, review results, and then refine the formulation again. This process can work, but it usually explores only a small part of the full design space. Modern coatings combine binders, fillers, pigments, and additives that interact across multiple scales. A slight change in binder chemistry, filler dispersion, curing conditions, or additive loading can produce large and sometimes unexpected shifts. These changes can be in adhesion, durability, or environmental resistance. The relationships between properties and components are nonlinear and difficult to map. Increasing one component does not always improve one property. It can also weaken another. Better corrosion resistance might reduce flexibility. Faster curing might affect adhesion. A filler that improves barrier performance in one system may create defects in another. Therefore, incremental testing often becomes time-consuming...


- Published: 2026-06-12
- Modified: 2026-06-09
- URL: https://www.plasticsengineering.org/2026/06/3d-printed-polymer-wrap-aims-to-reduce-dialysis-site-failure-011403/
- Categories: 3D Printing/Additive Manufacturing, Bioplastics, Design, Editor's Choice Technical Paper, Education & Training, Industry, Materials, Medical, People, Process, Resins, Trending

Advanced polymer engineering and 3D printing technology power SelfWrap, VenoStent’s breakthrough vascular implant.

Advanced polymer engineering and 3D printing technology power SelfWrap, VenoStent’s breakthrough vascular implant. One in eight people worldwide suffers from chronic kidney disease (CKD). As CKD progresses, loss of kidney function continues, potentially reaching end-stage kidney disease (ESKD). Generally, CKD is managed by medication and lifestyle changes to slow damage, but ESKD requires immediate life-sustaining treatments like hemodialysis (dialysis) or kidney transplants. In the U. S. , about 480,000 ESKD patients receive hemodialysis according to the National Institute of Health, U. S. Renal Data System. Dialysis requires a surgical procedure to create a vascular access site to conduct ongoing treatment. Of the 480,000 patients, a 50-60% failure rate of dialysis vascular access sites occurs in the first year, according to a meta-analysis published in the American Journal of Kidney Disease. One Houston, Texas area start-up is aiming to improve the lives of patients undergoing ESKD treatment. You can also read: 3D Printing, Hydrogels, and Polymers in Modern Wound Care VenoStent is a clinical-stage therapeutic medical device company located in the heart of the Texas Medical Center. The team is a blend of cross-disciplinary experts in biomedical engineering, materials engineering, and medical 3D-printing. Their pioneering team has developed SelfWrap, a novel tissue engineering technology for vascular surgery and dialysis treatment. In 2023, VenoStent secured a 16-million-dollar Series A round, announcing an FDA Investigational Device Exemption for U. S. clinical trials. Most recently, they enrolled their first 200‑subject U. S. clinical trial in the SAVE‑FistulaS Clinical Trial. SelfWrap: How It Works SelfWrap...


- Published: 2026-06-11
- Modified: 2026-06-09
- URL: https://www.plasticsengineering.org/2026/06/ai-enabled-design-of-sustainable-flame-retardant-composites-011397/
- Categories: Artificial Intelligence, Bioplastics, Business, Composites, Design, Education & Training, Industry, Industry 4.0, Materials, Process, Resins, Results, Strategy, Sustainability, Thermoplastics, Trending

AI is helping researchers design sustainable flame-retardant biodegradable composites faster by optimizing fire performance, strength, and material efficiency.

AI is helping researchers design sustainable flame-retardant biodegradable composites faster by optimizing fire performance, strength, and material efficiency. Regulations, environmental concerns, and consumer interests increasingly demand the development of biodegradable polymer composites. Subsequently, sustainable flame-retardant materials ensure fire safety without reliance on halogenated or persistent chemicals. You can also read: Advancing Fire Performance with Flame-Retardant Fiber Reinforced Thermoplastic Composites. Integrating sustainable flame retardants with biodegradable polymer composites can help manufacturers meet safety and performance targets. Current flame-retardant design strategies rely on trial and error, with limited tunability and high time and resource requirements. Now, AI-driven design methods are accelerating research and design for flame-retardant materials. Machine learning can help predict biodegradation behavior. Figure courtesy of Advancing Sustainability: Biodegradable Electronics and New Materials through AI and Machine Learning. New Developments in Sustainable Flame Retardants Recently developed sustainable flame retardants include bio-derived phosphorus-containing molecules, mineral-based systems, and metal-organic frameworks. When a polymer encounters heat, bond scission and volatilization generate combustible gases. Flame retardants alter degradation pathways and suppress combustion. Sustainable flame retardants can enhance char formation, suppress flame spread, and reduce heat release from biodegradable polymers. Melt blending, fiber surface treatment, chemical grafting, and hybrid nanostructuring can integrate sustainable flame retardants into biodegradable matrices. Challenges of Incorporating Sustainable Flame Retardants Biodegradable polymer composites often require a high additive loading to achieve acceptable flame retardancy. Requirements can exceed 40 wt. %, compromising mechanical performance and making material processing difficult. When using mineral-based flame retardants, this can reduce the composite’s transparency or toughness. Additionally,...


- Published: 2026-06-10
- Modified: 2026-05-22
- URL: https://www.plasticsengineering.org/2026/06/choosing-the-right-recycling-technology-for-each-application-011318/
- Categories: Automotive & Transportation, Building & Construction, Business, Circular Economy, Composites, Education & Training, Industry, Materials, Medical, Packaging, Process, Recycling, Recycling, Resins, Sustainability, Thermoplastics, Thermosets, Trending

Recycling technologies vary widely depending on feedstock quality and target performance. Selecting the right pathway determines whether circularity delivers real value or compromises material performance.

Recycling technologies vary widely depending on feedstock quality and target performance. Selecting the right pathway determines whether circularity delivers real value or compromises material performance. Not All Recycling Is the Same Recycling often appears as a single concept, but in practice, it encompasses multiple technologies with distinct capabilities and limitations. Mechanical recycling remains the most familiar approach, where processors grind plastic parts into flakes and remelt them into new products. However, recycling can also involve solvent-based separation, depolymerization into monomers, or even conversion back into feedstock through chemical processes. Each pathway serves a different purpose and depends on the material's condition. Selecting the appropriate technology requires evaluating several factors, including waste-stream purity, material degradation, molecular-weight retention, and the intended application of the recycled resin. You can also read: Interest Grows in Chemical Recycling. Mechanical Recycling: The First Option Mechanical recycling should be the preferred option when the waste stream is sufficiently pure or can be effectively sorted. It remains the most energy-efficient pathway and typically delivers the lowest carbon footprint. However, sorting introduces limitations. While it produces a high-purity fraction, it also generates residual mixed waste that cannot be processed by conventional mechanical methods. When polymer chains retain sufficient molecular weight and structural integrity, mechanical recycling enables reprocessing without significant loss of performance. In these cases, it offers the most efficient route to circularity. Recent developments show that even traditionally difficult materials can enter this pathway. BASF demonstrated that modified cross-linked polyurethane foams can be liquefied and reintroduced into polyol...


- Published: 2026-06-09
- Modified: 2026-05-21
- URL: https://www.plasticsengineering.org/2026/06/digital-twins-transform-injection-molding-training-011388/
- Categories: Artificial Intelligence, Education & Training, Industry, Industry 4.0, Injection Molding, People, Process, Software, Trending

Virtual injection molding training using digital twins improves skills, cuts costs, and reduces material waste.

Virtual injection molding training using digital twins improves skills, cuts costs, and reduces material waste. Injection molding demands precise control of thermal, rheological, and mechanical variables. Operators must understand melt flow behavior, cooling kinetics, and machine parameters to produce defect-free parts. Traditional training relies heavily on physical machines, which limit access, increase cost, and generate material waste. You can also read: Plastics Training: The Secret of Competitiveness. Vicente Jover, Peris, Juan Luis Gámez Martínez, Sergio Ferrándiz Bou, and Amparo Jordá Vilaplana propose a different approach. They use digital twins within a metaverse environment to train users in injection molding operations. Their work shifts training from physical trial-and-error to controlled, data-driven simulation. Building a Digital Twin of the Process The authors develop a virtual replica of an injection molding system that integrates process, physics, and machine behavior. This digital twin reproduces key stages of the cycle, including filling, packing, and cooling. Users interact with the system in real time, adjusting parameters such as injection speed, mold temperature, and holding pressure. The model captures cause-and-effect relationships between processing conditions and part quality. For example, users can observe how changes in packing pressure influence shrinkage or how cooling time affects residual stresses. This approach allows trainees to explore process windows without risking defective production. The metaverse environment enhances this experience by creating an immersive interface. Users not only input parameters; they also navigate and manipulate the process as if they were operating a real machine. User navigation in the metaverse environment. Courtesy of...


- Published: 2026-06-08
- Modified: 2026-05-21
- URL: https://www.plasticsengineering.org/2026/06/recycled-content-claims-and-the-mass-balance-debate-011384/
- Categories: Automotive & Transportation, Bioplastics, Building & Construction, Circular Economy, Compounding, Education & Training, Industry, Materials, Medical, Packaging, People, PET, Polycarbonate, Polyethylene, Polyolefins, Polypropylene, Process, Recyclate, Recycling, Regulation, Resins, Sustainability, Thermoplastics, Trending

As regulators, NGOs, and manufacturers dispute recycled-content rules, mass balance has become a credibility test for circular plastics claims.

As regulators, NGOs, and manufacturers dispute recycled-content rules, mass balance has become a credibility test for circular plastics claims. Mass balance has become one of the most important and disputed concepts in the circular plastics sector. Industry has long presented it as a technically feasible accounting framework for introducing renewable or recycled feedstocks into large-scale chemical manufacturing. This rationale reflects the design of many industrial assets, where continuous mixed-feed operations dominate. In these systems, physical segregation would increase technical difficulty, add operational complexity, and raise costs. You can also read: What Comes Next for EPS Recycling in the UK. Mass balance addresses this constraint through a certified accounting framework. A manufacturer adds a defined amount of recycled or renewable input to the process and assigns that amount to selected outputs under chain-of-custody rules. This approach lets companies integrate alternative feedstocks without separate production lines, physical segregation, or changes in product performance. Why Industry Supports the Method In the mass balance approach, recycled feedstock enters a mixed production system and manufacturers assign the recycled share to selected outputs rather than physically segregating the material. Courtesy of World Plastics Council. Mass balance appeals to producers because it fits existing industrial infrastructure. In chemical recycling, renewable feedstock integration, and specialty materials manufacturing, inputs often enter continuous mixed-feed systems. In these systems, early blending makes it difficult to trace a specific feedstock fraction to one final product. Mass balance addresses this constraint through a certified accounting framework. A manufacturer adds a defined amount of...


- Published: 2026-06-05
- Modified: 2026-05-19
- URL: https://www.plasticsengineering.org/2026/06/large-scale-am-redefines-composite-tooling-011368/
- Categories: 3D Printing/Additive Manufacturing, Aerospace, Automotive & Transportation, Business, Education & Training, Equipment, Industry, Materials, Process, Resins, Trending

Carbon fiber-reinforced thermoplastics enable large molds, but material behavior and joining strategies still define performance limits.

Carbon fiber-reinforced thermoplastics enable large molds, but material behavior and joining strategies still define performance limits. Aerospace and automotive manufacturers rely on large molds to produce composite parts through layup and compression molding. Traditional tooling uses machined metals, which require long lead times and generate significant material waste. Large-scale additive manufacturing (LSAM) provides an alternative by depositing material only where needed. Research led by Eduardo Barocio demonstrates that LSAM can produce large composite tooling using high-performance thermoplastics, reducing both manufacturing time and material consumption compared to conventional machining. Printing Large Molds with CF Enhanced Thermoplastics LSAM systems use pellet-fed extrusion to manufacture large components at high deposition rates. This approach allows engineers to produce molds at a meter scale for composite processing applications. Recent work shows that industries can use LSAM to fabricate and reuse molding and tooling components using carbon fiber-reinforced thermoplastics. The study demonstrates that these materials support large-format applications while enabling material recovery and reuse, reducing overall environmental impact. Carbon Fiber Reinforcement Improves Stiffness and Dimensional Stability in LSAM molds. Material performance plays a critical role in replacing metal tooling. Carbon fiber-reinforced thermoplastics increase stiffness and reduce thermal expansion compared to unfilled polymers. Research on LFAM materials shows that fiber reinforcement improves dimensional stability and mechanical performance, both of which are essential for maintaining mold geometry during composite processing. However, the same study highlights that processing conditions strongly influence final properties, and printing introduces anisotropy. Dimensional Accuracy Remains a Key Challenge The layer-by-layer deposition process creates directional...


- Published: 2026-06-04
- Modified: 2026-05-18
- URL: https://www.plasticsengineering.org/2026/06/no-assembly-required-bio-based-resin-for-monolithic-soft-robotics-011363/
- Categories: 3D Printing/Additive Manufacturing, Bioplastics, Design, Education & Training, Electrical & Electronics, Equipment, Industry, Materials, Medical, Process, Resins, Sensors, Thermoplastics, Trending
- Tags: additive manufacturing

Monolithic 3D printing with bio-based resins enables origami-inspired soft robotics without assembly, combining sustainability and design complexity.

Monolithic 3D printing with bio-based resins enables origami-inspired soft robotics without assembly, combining sustainability and design complexity. Soft robotic systems typically rely on multi-material architectures that require sequential processing steps. These approaches combine elastomers, reinforcements, and embedded features, but introduce interfaces that can limit durability and complicate manufacturing. They also constrain geometric complexity and slow down design iteration. Montazeri et al. propose a different route: fabricate soft robotic structures as fully integrated, monolithic components using vat photopolymerization. By eliminating interfaces and post-processing assembly, the method enables direct translation of complex geometries into functional devices. You can also read: Designing Polymeric Composites at the Voxel Scale with Multi-Material Jetting. Bio-Based Photopolymers for Additive Manufacturing Bio-based resin performance and printability for DLP processing. Courtesy of Monolithic 3D Printing of Origami‐Inspired Soft Robotics from Sustainable Bio‐Based Resin - Montazeri - 2026 - Advanced Science - Wiley Online Library. The study formulates a bio-based photocurable resin tailored for digital light processing (DLP). The resin incorporates renewable building blocks while maintaining the rheological and photochemical characteristics needed for high-resolution printing. Mechanical characterization shows elastomeric behavior suitable for large, reversible deformations. The material supports repeated mechanical loading without catastrophic failure, enabling soft robotic actuation. At the same time, the formulation remains compatible with standard DLP processing windows, enabling accurate fabrication of thin features and hinges. The resin formulation balances viscosity and reactivity to remain compatible with DLP processing while preserving feature fidelity. Rheological characterization shows a temperature-dependent viscosity profile that supports recoating and layer uniformity, while...


- Published: 2026-06-03
- Modified: 2026-05-18
- URL: https://www.plasticsengineering.org/2026/06/ultrasonic-assisted-extrusion-a-new-route-to-high-barrier-hdpe-011357/
- Categories: Circular Economy, Education & Training, Extrusion, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, Polyethylene, Polyolefins, Process, Regulation, Resins, Sustainability, Thermoplastics, Trending
- Tags: barrier packaging

Ultrasonic extrusion boosts HDPE barrier performance, offering a path to recyclable, monomaterial packaging without multilayers.

Ultrasonic extrusion boosts HDPE barrier performance, offering a path to recyclable, monomaterial packaging without multilayers. Flexible packaging relies heavily on multilayer structures to achieve an oxygen barrier. Processors routinely combine materials such as ethylene-vinyl alcohol (EVOH) with polyolefins to meet shelf-life requirements, but these solutions complicate recycling and conflict with the growing push toward monomaterial packaging. The industry widely uses high-density polyethylene (HDPE) because it is readily recyclable and inherently exhibits limited oxygen-barrier properties. You can also read: Elevating PEEK Composites with Glass Fiber. Recent work by Mansoureh Jamalzadeh and co-authors proposed a different approach: instead of modifying material formulations, they modify the processing conditions. Their study demonstrates that ultrasonic-assisted extrusion can significantly alter the crystalline structure of HDPE, leading to measurable improvements in barrier performance. This positions processing, not chemistry, as a lever for designing next-generation recyclable packaging. Coupling Ultrasound with Flow-Induced Crystallization The study integrates ultrasound into the extrusion process to intensify flow-induced crystallization (FIC). Under conventional extrusion, polymer chains experience shear and elongational flow, which induces some degree of molecular orientation. However, chain relaxation often limits this effect. Ultrasonic-assisted extrusion processing schematic with different plates (anvil, rectangular opening (blank), and hole pattern) and crystal structure evolution under both shear flow and ultrasonic field. Courtesy of Ultrasonic-Assisted Extrusion Processing for Enhancing Physical Properties of High-Density Polyethylene by Flow-Induced Crystallization. By introducing ultrasonic energy during extrusion, the process enhances chain mobility and alignment under flow. The authors show that this combination promotes the formation of more oriented crystalline structures...


- Published: 2026-06-02
- Modified: 2026-05-14
- URL: https://www.plasticsengineering.org/2026/06/static-and-dust-in-conveying-systems-defects-risks-safety-011376/
- Categories: Auxiliaries, Business, Equipment, Industry, Materials, People, Sustainability, Trending

Static and dust in pneumatic conveying can cause fines, false alarms, filter loading, defects, and safety risks. Learn the causes clearly.

Static and dust in pneumatic conveying can cause fines, false alarms, filter loading, defects, and safety risks. Learn the causes clearly. Pneumatic conveying systems do more than transfer pellets from storage to process. They also govern triboelectric charging, pellet attrition, fines transport, filter loading, sensor reliability, and dust-related safety risk. Conveying velocity, line geometry, bend impacts, air dryness, and grounding continuity all affect charge accumulation and particulate generation. You can also read: Resin Drying: The Energy Elephant Hiding in Plain Sight. Many plastic plants treat those effects as isolated maintenance problems. In practice, they often indicate deeper issues in conveying design and operating conditions. When engineers treat static and dust as system-level variables, they can reduce defects, false alarms, downtime, and operational risk. Electrostatic Charge Development During Pellet Conveying Static charge develops as pellets, regrind, and fines interact with pipe walls, elbows, diverters, and each other during transport. In plastics conveying, that charge often persists because polymers exhibit limited electrical conductivity. Low relative humidity further reduces charge dissipation. High conveying velocity can intensify charging by increasing collision frequency, wall impact, and frictional contact along the line. Those same conditions can also increase pellet attrition and fines generation. Mechanical Drivers of Pellet Attrition and Fines Generation Many conveying problems stem from excessive mechanical loading within the transport line. Tight-radius elbows, abrupt cross-section changes, long dilute-phase runs, and excessive pickup velocity increase particle-wall impacts, sliding friction, and pellet-to-pellet collisions. These conditions promote attrition, generate fines, and increase dust loading. Industry guidance on...


- Published: 2026-06-01
- Modified: 2026-05-13
- URL: https://www.plasticsengineering.org/2026/06/kubik-building-brick-by-brick-with-plastic-waste-011340/
- Categories: Building & Construction, Business, Circular Economy, Education & Training, Extrusion, Industry, Materials, People, Process, Recyclate, Recycling, Recycling, Resins, Sustainability, Trending

Upcycled plastic becomes durable, low‑carbon building materials as Kubik transforms waste into affordable, interlocking components for sustainable construction.

Upcycled plastic becomes durable, low‑carbon building materials as Kubik transforms waste into affordable, interlocking components for sustainable construction. According to the Organization for Economic Co-operation and Development (OECD), the amount of plastic waste produced worldwide is expected to triple to more than 1,000 million tons by 2060. It is estimated that developed countries will continue to generate the most plastic waste per person. You can also read: Polypropylene Waste for Binder Use in Building Materials. Still, regions such as Africa and Asia are expected to see the fastest growth due to rapid population growth and urbanization. Even so, African startups have embraced and integrated green technologies to mitigate climate change and reduce carbon footprints. A Standout in East Africa’s Green Technology Sector Kubik, headquartered in Addis Ababa, Ethiopia, is an environmental technology company that transforms plastic waste into affordable, low-carbon building materials. Founded in 2021 by Kidus Asfaw, Kubik is a key standout in the region’s green technology sector. Their mission to combat climate change and reduce construction carbon footprints aims to help solve Ethiopia’s housing crisis. They are tackling these problems by producing plastic construction bricks from hard-to-recycle plastics. Kubik is combining positive social impact, circular-economy principles, and low-carbon construction as scalable solutions to the region’s most pressing challenges, such as the affordable-housing shortage and plastic-waste management. Transforming Plastic Waste to Structural Goods The startup technology involves converting difficult-to-recycle plastic waste, like polyethylene, polypropylene, and polystyrene, into durable, structural building materials. Though their source stream requirements are not public,...


- Published: 2026-05-29
- Modified: 2026-05-12
- URL: https://www.plasticsengineering.org/2026/05/polyolefin-hydrogenolysis-boosts-fuel-yield-with-new-catalysts-011330/
- Categories: Business, Editor's Choice Technical Paper, Education & Training, Industry, Materials, Polyethylene, Polyolefins, Process, Recycling, Resins, Trending

A novel catalytic approach overcomes the limitations of polyolefin hydrolysis, a promising technology for a circular fuel-waste economy.

A novel catalytic approach overcomes the limitations of polyolefin hydrolysis, a promising technology for a circular fuel-waste economy. Polyolefin hydrogenolysis enables the upcycling of waste under mild reaction conditions, with a controllable product distribution. During hydrogenolysis, polymers undergo C-H activation, C-C cleavage, and hydrogenation/desorption, thereby upcycling them into liquid alkane fuels. Polymer chains have more degrees of freedom during hydrogenolysis compared to small molecules. Thus, this process results in a reduction of entropy. At the same time, C-H activation is endothermic, making it thermodynamically unfavorable. You can also read: Redefining Recycling: Depolymerization of PET Optimizing the Process Recent research has focused on catalyst design to reduce configurational entropy and address these challenges. These catalysts limit configurational entropy by restricting the domain space that is available to polymer chains. A novel strategy proposes a universal surface-polarity-reconstruction strategy for traditional supported metal catalysts. By matching the polarity between the polymer and support, this method overcomes thermodynamic limitations during polyolefin hydrogenolysis. Researchers constructed a catalyst with optimized surface polarity to improve yields of gasoline and diesel components through polyolefin hydrolysis. Figure courtesy of Entropy Engineering for the Efficient Hydrogenolysis of Waste Polyolefins. Catalyst Creation In this study, researchers synthesized ruthenium (Ru)-based catalysts, including Ru/CeO2, Ru/ZrO2, Ru/AlO3, and Ru/TiO2. Then, they modified each using a silane coupling reaction. This allows tuning of the catalyst’s surface polarity, thereby inducing an entropy-confinement effect. Once the catalysts were prepared, researchers conducted the polyolefin/alkane hydrogenolysis in a stainless-steel autoclave. Researchers evaluated Ru-CeO2’s performance with a variety of volumes...


- Published: 2026-05-28
- Modified: 2026-06-22
- URL: https://www.plasticsengineering.org/2026/05/water-packaging-design-turning-a-commodity-into-a-brand-011288/
- Categories: Blow Molding, Design, Food Packaging, Industry, Materials, Packaging, People, PET, Process, Resins, Sustainability, Trending

Water packaging transforms a commodity into a brand through design, structure, and material storytelling across sustainability and performance.

Water packaging transforms a commodity into a brand through design, structure, and material storytelling across sustainability and performance. Water is elemental, universal, and essential. However, the bottle that contains it carries the full weight of meaning, distinction, and desire. In fact, a principle known as sensation transference ensures that the physical attributes of a container directly shape how consumers perceive its contents. As a result, qualities such as elegance, clarity, slimness, and texture become inherent to the product in the consumer’s mind. For this reason, the shape of a water bottle is never neutral. Instead, every curve, surface finish, and structural decision communicates a three-dimensional story that precedes any label. Ultimately, the bottle itself becomes the first and most powerful brand asset. You can also read: Digital Product Passports: Revolutionizing Transparency and Sustainability. Designers working with PET have explored an extraordinary range of forms. Each one functions as a silent argument about origin, purity, sophistication, or accessibility. The challenge lies in creating structural distinction within the constraints of blow molding, lightweighting targets, and palletization efficiency. Engineering and storytelling converge in every design decision. Source, Science, and Narrative Territories Orizon's bespoke PET bottle features a structural design that wraps around the product with a protective, enclosing gesture, evoking the idea of a hidden treasure emerging from deep Patagonian springs. The form language communicates preciousness and origin through tactile cues engineered directly into the container's geometry. Design by Tridimage. Water brands typically organize their identity around two fundamental narrative territories. On one...


- Published: 2026-05-27
- Modified: 2026-05-12
- URL: https://www.plasticsengineering.org/2026/05/self-lubricating-peek-bushings-for-heavy-duty-equipment-011323/
- Categories: Auxiliaries, Business, Equipment, Hybrid Manufacturing, Industry, Materials, People, Process, Resins, Thermoplastics, Trending

Engineers deploy self-lubricating PEEK composites to eliminate external lubrication and prevent wear on heavy-duty rotating equipment.

Engineers deploy self-lubricating PEEK composites to eliminate external lubrication and prevent wear on heavy-duty rotating equipment. Traditional bronze bearings require hydrostatic oil grooves, which fail under heavy-load, low-speed conditions where rotational velocities cannot generate dynamic fluid films. Operators constantly battle particle-induced scratches and catastrophic leakage. Engineers solve this vulnerability by deploying self-lubricating Polyetheretherketone (PEEK) composite bearing bushes. These advanced polymers utilize internal solid lubricants and high-modulus fibers to spontaneously deposit robust transfer films directly onto the metal counterface, eliminating the need for external liquid lubrication. You can also read: Elevating PEEK Composites with Glass Fiber Tribological Phase Transitions Material scientists engineer these PEEK matrices by integrating Polytetrafluoroethylene (PTFE), short carbon fibers, graphite, and poly-p-phenylene-terephthalamide. During active rotation, high-modulus reinforcing fibers bear primary mechanical normal loads. These fibers restrict plastic deformation and prevent sharp metal micro-convexities from gouging the composite. Simultaneously, extreme contact pressure extrudes the soft PTFE component. This solid lubricant fills localized wear grooves and established a protective layer. Under operational pressures reaching 33 MPa, stripped carbon fibers and solid lubricants undergo a self-polymerization reaction. This reaction thoroughly coats the fiber surfaces, generating powerful mechanical anchoring forces that prevent interfacial debonding. By actively depositing a sulfur-rich transfer film onto the metallic counterpart, these composites allow designers to run heavy-duty rotating equipment in completely dry or seawater environments. Three-layer sliding bearing bush structure. Courtesy of Friction and Wear Performance of a Hydraulic Motor Roller/Piston Pair Contact Lined with the Self-Lubricating Bearing Bush Modified by PEEK. Evaluating Hard Performance Metrics Engineers...


- Published: 2026-05-26
- Modified: 2026-05-22
- URL: https://www.plasticsengineering.org/2026/05/why-food-grade-pcr-supply-still-lags-in-food-packaging-011380/
- Categories: Business, Circular Economy, Education & Training, Food Packaging, Industry, Materials, Packaging, PET, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Recycling, Regulation, Resins, Sustainability, Thermoplastics, Trending

Recycled-content mandates are accelerating, but the supply of compliant recycled polyolefins for food packaging remains constrained.

Recycled-content mandates are accelerating, but the supply of compliant recycled polyolefins for food packaging remains constrained. The plastics industry has entered a more demanding phase of circularity. For packaging converters, recycled content is no longer a voluntary design objective or a brand-led sustainability preference. It is becoming a regulatory requirement. In food-contact applications, however, one constraint continues to limit progress: the availability of food-grade post-consumer resin. You can also read: FDA Accelerates Approvals for Recycled Plastics in Food Packaging. That bottleneck is especially visible in polypropylene and polyethylene, where demand for recycled content continues to rise but the supply of resin capable of meeting both regulatory and performance requirements has not kept pace. As a result, the market now faces a structural mismatch between mandated recycled-content targets and the limited volume of food-contact-compliant material available to meet them. Under the EU PPWR, by 2030 contact-sensitive PET packaging must contain at least 30% recycled content, while other contact-sensitive plastic packaging must contain at least 10%. Why Food Contact Changes the Equation The constraint goes beyond recycling capacity. Food-contact PCR depends on purification efficiency, feedstock traceability, and regulatory acceptance. For food packaging, recycled polymer must not only re-enter production but also satisfy strict safety thresholds for contaminants associated with prior use, misuse, additives, inks, adhesives, and nonfood applications. EU Regulation (EU) 2022/1616 governs recycled plastics for food contact, while EFSA currently bases its evaluations on post-consumer mechanical PET recycling technologies. In the U. S. , the FDA issues favorable opinions for specific...


- Published: 2026-05-25
- Modified: 2026-05-12
- URL: https://www.plasticsengineering.org/2026/05/childrens-packaging-design-balancing-play-safety-and-trust-011283/
- Categories: Decorating & Coatings, Design, Food Packaging, Industry, Materials, Packaging, People, Process, Resins, Toys, Trending

Children’s packaging design blends sensory appeal, safety, and sustainability to engage kids while building trust with parents.

Children’s packaging design blends sensory appeal, safety, and sustainability to engage kids while building trust with parents. Packaging for children operates across multiple dimensions simultaneously. It must communicate delight and nutrition, safety and exploration, parental trust and childhood imagination. Achieving this balance requires more than visual appeal. It demands a deep understanding of how children perceive, handle, and interpret the physical world. You can also read: How To Talk About Plastics With Consumers. The Sensory Architecture of Childhood Children do not read packaging the way adults do. They feel it, taste it with their eyes, grab it, and squeeze it. Color is the first language of early childhood, with primary tones and high-saturation hues that trigger attention and stimulate cognitive development. As children grow, cultural codes and media influence begin to shape their chromatic preferences, creating a moving target that skilled designers must track with care. Fazer Vilpuri children's bread range deploys a single monster-mouth character system across four SKUs, using the transparent film window as the creature's jagged teeth to reveal the actual product inside as part of the graphic narrative. Design by Hasan & Partners. The structural dimension of a package carries equal weight. Tactile design for young hands means thinking in terms of grip proportions, safe edges, and textural surfaces that invite fine motor engagement. A well-formed bottle can quietly encourage developmental skills while delivering a product, transforming a functional object into an instrument of learning disguised as play. Appetite, Health, and the Dual Audience Packaging for...


- Published: 2026-05-22
- Modified: 2026-05-11
- URL: https://www.plasticsengineering.org/2026/05/packaging-embellishment-as-brand-storytelling-in-premium-design-011273/
- Categories: Business, Decorating & Coatings, Design, Food Packaging, Industry, Packaging, People, Process, Trending

Packaging embellishment turns finishing techniques into brand storytelling through texture, materials, and tactile consumer experience.

Packaging embellishment turns finishing techniques into brand storytelling through texture, materials, and tactile consumer experience. In premium packaging, the distance between decoration and meaning is measured in microns of foil, the depth of a dry stamp, and the texture of a cotton substrate. Embellishment has evolved beyond aesthetic enhancement to become the physical materialization of brand identity, a tactile language that communicates values before a single word is read. Each finishing technique carries narrative weight, transforming packaging into a sensory experience that connects product and consumer on an intimate level. You can also read: The Art of the Small: Strategies for Success in Micro Molding. Touch as the First Conversation The human hand perceives what the eye cannot fully appreciate. When fingertips encounter a dry-stamped logo, they discover layers of intention embedded in the substrate itself. This haptic dimension transforms passive observation into active exploration, inviting consumers to physically engage with brand heritage and craftsmanship. Additionally, silkscreen printing directly on plastic containers creates a permanent bond between the message and the material. The slight relief and subtle texture variation become a signature that consumers can literally feel and remember. In markets saturated with visual noise, touch emerges as the most intimate and memorable channel of brand communication. Materials That Speak Authenticity Sekkisei Miyabi Cream Nectar executes Japanese luxury codification through artisanal material vocabulary: hand-etched geometric botanical pattern on metallic spherical vessel evokes traditional craftsmanship. Design by Kosé Corporation. Substrates communicate craftsmanship through their natural irregularity. The slightly textured surface plays...


- Published: 2026-05-21
- Modified: 2026-05-12
- URL: https://www.plasticsengineering.org/2026/05/rheological-additives-for-low-roughness-aerospace-coatings-011279/
- Categories: Additives & Colorants, Aerospace, Decorating & Coatings, Design, Education & Training, Finishing, Industry, Materials, Process, Silicones, Trending

The need to reduce aerodynamic drag in modern aircraft leads to a focus on the surface roughness of external coatings.

The need to reduce aerodynamic drag in modern aircraft leads to a focus on the surface roughness of external coatings. Experimental aerodynamic studies show that roughness variations on the order of micrometers can cause earlier transition of the boundary layer. Specifically, that transition from laminar to turbulent results in measurable increases in drag and fuel consumption. Therefore, designing coatings with a rheological profile suitable for spray applications with minimal surface texture is a critical issue in aerospace. You can also read: Self-Healing Coatings for Automotive Applications. Surface Roughness and Boundary Layer The connection between rheology and aerodynamics manifests in the final film's roughness and its effect on the boundary layer. Studies by AIAA and NASA have analyzed how roughness features distributed across the surfaces of airfoils induce boundary-layer transition. For example, controlled variations in the roughness height on NACA airfoils modify the boundary-layer thickness and turbulence intensity. As a result, these variations affect the transition point and the skin drag of the whole lifting surface. Laminar boundary layer is desirable to maximize aerodynamics performance. The onset of the transition is multivariable dependent, being surface roughness one of the most important variables. Courtesy of Characteristics and Effects of Laminar Separation Bubbles on NREL S809 Airfoil Using the Gamma-Reynolds Transition Model. Open Access CC BY 4. 0. In transport aircraft, the surface friction accounts for approximately 50% of the total drag budget. Therefore, it is critical to quantify the impact of surface roughness on overall aerodynamic performance in the transonic regime. Experiments...


- Published: 2026-05-20
- Modified: 2026-05-12
- URL: https://www.plasticsengineering.org/2026/05/mechanical-recycling-of-polyolefins-in-food-packaging-011336/
- Categories: Circular Economy, Education & Training, Food Packaging, Industry, Materials, Packaging, People, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Recycling, Resins, Sustainability

Regulations are encouraging the development of food-safe recycling methods for polyolefins.

Regulations are encouraging the development of food-safe recycling methods for polyolefins. In the European Union (EU), the Packaging and Packaging Waste Regulation (PPWR) specifies minimum post-consumer waste (PCW) requirements for certain applications. For food packaging, this amount is 10% by 2030. Polyolefins exhibit barrier properties against grease, oil, and aromatic compounds, making them a common choice for food packaging. The amount of recycled polyolefins meeting food-grade quality criteria must increase to meet regulatory requirements. Designing for recycling, improving sorting, and developing more effective washing technologies can help achieve this goal. You can also read: AI Screens 7. 4M Polymers for Recyclable Food Packaging. Polyolefins make up a large share of the EU’s market demand for plastic goods. Figure courtesy of An Overview of Enhancing Polyolefin Recycling in Food Packaging: Navigating New EU Regulations and Design for Recycling; data from 2021. Use of Polyolefins in Food Packaging Polyolefins have a low water vapor transmission rate (WVTR). This makes them suitable for food packaging, where protection from water ingress prevents early spoilage. Packaged fruits and vegetables continue to respire after harvest; thus, polyolefin packaging for these products requires perforation. Polyolefins’ low WVTR and good mechanical properties also make them a common choice for trays, cups, and dairy product packaging. For certain applications, commercially-available recyclable polyolefin films can substitute traditionally non-recyclable materials. These films typically have a thin, high barrier layer (often ethyl vinyl alcohol) embedded in the middle. By combining strong barrier properties with good compatibility, these multilayer films provide excellent performance...


- Published: 2026-05-20
- Modified: 2026-05-11
- URL: https://www.plasticsengineering.org/2026/05/chopped-fiber-compounding-enters-injection-molding-011294/
- Categories: Aerospace, Automotive & Transportation, Circular Economy, Composites, Editor's Choice Technical Paper, Education & Training, Equipment, Industry, Injection Molding, Materials, Polyolefins, Process, Resins, Sustainability, Thermoplastics, Thermosets, Trending

New CFP technology enables direct fiber compounding in injection molding, reducing costs, improving flexibility, and lowering CO₂ emissions.

New CFP technology enables direct fiber compounding in injection molding, reducing costs, improving flexibility, and lowering CO₂ emissions. A new injection molding approach now enables direct feeding of chopped fibers into the plasticizing unit, simplifying compounding and reducing processing steps. As a result, manufacturers can lower material costs, improve process efficiency, and reduce CO₂ emissions across production lines. You can also read: Plastics Injection Molding: Definition, Benefits and Applications. Integrating Compounding into Injection Molding Injection molding is increasingly integrating previously separate processing steps, including part finishing and fiber compounding, into a single operation. Historically, manufacturers relied on external compounding processes to prepare fiber-reinforced materials before feeding them into injection molding machines. Fiber-reinforced compounds remain widely used, particularly in automotive applications, to increase stiffness while maintaining the lightweight advantages of polymer materials. However, traditional production requires twin-screw extrusion, where high shear ensures proper dispersion of fibers within the polymer matrix. Direct Fiber Feeding with CFP Technology KraussMaffei introduces a new approach that feeds chopped fibers directly into the injection molding machine, eliminating the separate compounding step entirely. Specifically, the process uses patented screw technology to incorporate chopped fibers directly into polypropylene during plasticization within the injection unit. The process, known as chopped fiber processing (CFP), introduces fibers at the feed throat using an additional metering system. Consequently, the screw design ensures controlled melting and homogeneous mixing without damaging the fiber structure or creating clusters. Cost, Flexibility, and Sustainability Advantages One of the primary advantages is cost reduction, as eliminating the compounding...


- Published: 2026-05-19
- Modified: 2026-05-11
- URL: https://www.plasticsengineering.org/2026/05/human-chaos-the-design-rebellion-against-algorithmic-perfection-011268/
- Categories: Artificial Intelligence, Business, Design, Education & Training, Food Packaging, Industry, Packaging, People, Trending

Packaging design embraces imperfection, using messy typography and human flaws to counter AI-driven aesthetics and build consumer trust.

Packaging design embraces imperfection, using messy typography and human flaws to counter AI-driven aesthetics and build consumer trust. Something curious happens when every design tool defaults to identical aesthetics. Photoshop's neural filters, Canva's AI companions, and countless generative platforms now produce the same flawless gradients, perfect symmetry, and eerily smooth synthetic faces. The result comes across as sterile, homogenized, and ultimately unconvincing. Consumers sense this disconnect immediately. When packaging arrives too polished, too algorithmically optimized, trust evaporates. You can also read: Plastics in Industrial Design: A Catalyst for Change. The Human Chaos movement emerges from this tension, offering packaging designers a vocabulary of deliberate disorder that speaks directly to our hunger for connection in an increasingly automated world. Where Machines Stumble, Designers Find Freedom The rebellion takes multiple forms, each exploiting creative territories where artificial intelligence remains demonstrably weak. Charcoal-smudged letterforms carry the evidence of physical pressure and gesture. Pen-and-ink illustrations reveal the tremor of a human hand, the hesitation before a stroke, the decision to leave a mistake visible. Typewriter fonts evoke mechanical imperfection from an analog era. Limited-run artist collaborations transform packages into collectible objects that celebrate singular vision over infinite reproduction. Designers also lean into compositional complexity that algorithms struggle to orchestrate convincingly: dense visual layering, mixed-media collages, overlapping textures that create depth through accident as much as intention. These approaches introduce nuance that automated systems cannot authentically replicate. Naive Aesthetics and the Power of Childlike Gesture Jolene´s artisan bakery identity exemplifies naive aesthetics through authentic childlike...


- Published: 2026-05-18
- Modified: 2026-05-11
- URL: https://www.plasticsengineering.org/2026/05/packaging-redesign-why-most-fail-and-what-drives-success-011263/
- Categories: Business, Design, Education & Training, Food Packaging, Industry, Packaging, People

In a marketplace where visual familiarity drives purchasing behavior, the decision to revolutionize packaging design is among the most consequential a brand can make.

In a marketplace where visual familiarity drives purchasing behavior, the decision to revolutionize packaging design is among the most consequential a brand can make. The tension between maintaining recognizable consistency and signaling meaningful change through radical redesign creates a paradox that defines modern packaging strategy. Research from William Caruso's doctoral study at the Ehrenberg-Bass Institute for Marketing Science, analyzing 1,336 redesigns from 744 brands across 25 categories, reveals a sobering reality: nine out of ten redesigns fail to deliver meaningful sales lift. You can also read: When Packaging Shape Speaks Louder Than Words. The Mathematics of Similarity Caruso's investigation established that the newly redesigned packaging measures only 47% similar to previous designs. This finding illuminates the industry's propensity for change, yet failure rates suggest change alone guarantees nothing. Research across thousands of tested designs reveals further nuance: 25% of revolutionary approaches result in lower purchase rates than predecessors, while evolutionary changes achieve half that rate. Revolutionary designs introduce shoppability benefits at a 25% rate, compared to 16% for evolutionary approaches. Packaging redesigns are more likely to succeed when they serve as an evolution, bridging the gap between what exists in consumers' minds and what appears on the shelf. Higher familiarity links directly to positive outcomes. Nuun hydration enhancer redesign demonstrates function-first communication architecture through dominant blue colorway signaling core benefit, strategic accent colors enabling subline navigation, and modular badge system replacing verbose copy with scannable claims. Design by Nestlé Health Science internal team. Courtesy of Designalytics. The Architecture of Recognition...


- Published: 2026-05-15
- Modified: 2026-05-07
- URL: https://www.plasticsengineering.org/2026/05/feedstocks-for-light-olefins-steam-cracking-decarbonization-011260/
- Categories: Business, Editor's Choice Technical Paper, Education & Training, Energy Generation, Equipment, Industry, Materials, Polyethylene, Polyolefins, Polypropylene, Resins, Strategy

Feedstock choice shapes olefin yields, costs, and emissions, driving new strategies in steam cracking and petrochemical decarbonization.

Feedstock choice shapes olefin yields, costs, and emissions, driving new strategies in steam cracking and petrochemical decarbonization. Global ethylene and propylene production continues to grow, driven by the demand for polyethylene, polypropylene, and elastomers. At the same time, petrochemical complexes face increasingly severe cost and decarbonization pressures. In this context, the choice of feedstock and cracking technology has become a key aspect for competitiveness. It defines the olefin yield, the co-product balance, and the plant's energy and carbon footprints. You can also read: Dynamics in Polymer Production: U. S. and Middle East Perspectives. Essential Raw Materials for Polymer Portfolios The different alkanes influence the efficiency of the cracking process, the degree of petrochemical integration and the downstream polymer production strategy. It also defines the production profile of a petrochemical plant, directly impacting on the availability of olefins for polymers. Producers derive Ethane from natural gas liquids, establishing it as the most efficient raw material for dedicated ethylene production. In steam cracking, it can achieve ethylene yields of 78–84% by weight. This production scheme makes it the preferred feedstock when the objective is to maximize polyethylene capacity with minimal operational complexity. However, the predominant raw material worldwide is light Naphtha, which is a liquid fraction of the petroleum refining process. Despite its more modest ethylene yield, around 29 to 34% by weight, Naphtha’s great strength lies in its product flexibility. Thanks to this flexibility, a single cracking unit can produce ethylene, propylene, butadiene, and BTX aromatics. This translates into downstream integration...


- Published: 2026-05-14
- Modified: 2026-05-04
- URL: https://www.plasticsengineering.org/2026/05/carbon-fiber-production-from-end-of-life-automotive-polymers-011254/
- Categories: Automotive & Transportation, Circular Economy, Composites, Education & Training, Industry, Materials, Process, Recyclate, Recycling, Recycling, Resins, Sustainability, Thermosets, Trending

New method converts automotive PP waste and CFRP scrap into recycled carbon fiber composites with improved mechanical performance.

New method converts automotive PP waste and CFRP scrap into recycled carbon fiber composites with improved mechanical performance. Every year, millions of vehicles reach the end of their useful life, and with them comes a growing environmental challenge. Certain vehicle parts rarely get a second life despite their potential for mechanical recycling and reuse. Bumpers, for instance, commonly made of PP, often end up in landfills due to difficulties in sorting and the lack of efficient recycling systems. Researchers also reveal that industries discard CFRP at an alarming rate. CFRP industries generate significant waste during manufacturing when performing cutting, trimming, and molding. This waste is commonly landfilled or incinerated despite retaining much of its original mechanical performance. Therefore, researchers successfully demonstrated the feasibility of solving both problems using an effective recycling strategy. You can also read: Recycled PETG Powers Carbon Fiber Filaments for 3D Printing. From End-of-Life Waste to Composite Feedstock Engineers developed an injection-molded composite combining recycled polymer matrices from end-of-life vehicle polypropylene car bumpers (rPP) with rCF obtained directly from manufacturing scrap. The researchers thermally processed the rCF in a muffle furnace at 500-700°C and then reduced it with a rotary cutter to 5mm. They recovered the rPP from four different front and rear bumpers, some useful, some damaged, and some unusable. They estimated that the life of the bumpers exceeded 15 years of use in each case. Afterward, they mixed and reduced the rPP with a fiber cutting machine to a standard length of 200mm to clean...


- Published: 2026-05-13
- Modified: 2026-05-04
- URL: https://www.plasticsengineering.org/2026/05/the-logistics-challenge-of-scaling-mechanical-recycling-011251/
- Categories: Business, Industry, Materials, People, Polyolefins, Process, Recycling, Regulation, Resins, Results, Sustainability, Trending

The circular plastics economy depends less on chemistry than on logistics. Collection, sorting, and cross-border waste flows now shape the quality and reliability of recycled polymers.

The circular plastics economy depends less on chemistry than on logistics. Collection, sorting, and cross-border waste flows now shape the quality and reliability of recycled polymers. Mechanical recycling begins long before the recycling plant processes any material. It starts inside municipal collection systems and commercial waste streams. These systems determine the quality of post-consumer resin before recyclers handle the material. A mixed collection often introduces contamination that later reduces the polymer's value. You can also read: Regulatory Frameworks for AI-Powered Plastic Sorting. Collection Systems Define Feedstock Quality Research published in Nature Communications Earth & Environment shows that inconsistent collection streams strongly influence the purity and yield of recycled polymers. Contaminants such as multilayer packaging, food residue, and incompatible polymers reduce recyclate performance. Sorting facilities must separate highly heterogeneous plastic waste under difficult conditions. Studies in the Journal of Cleaner Production report that high contamination rates require recyclers to discard large volumes of material. These losses raise costs and reduce the supply of high-quality post-consumer resin. Sorting Infrastructure Becomes a Strategic Asset Sorting technology is now at the core of mechanical recycling logistics. Modern facilities rely on optical sorting, AI classification, and automated material handling. Companies such as TOMRA use near-infrared sensors to identify polymer types at high speeds. New AI systems from Greyparrot analyze waste streams and identify packaging formats in real time. Advanced sortation systems from AMP Robotics automate many operations at material recovery facilities. Materials Recovery Facilities now route incoming plastic waste across mechanical, chemical, and thermochemical recycling...


- Published: 2026-05-12
- Modified: 2026-05-01
- URL: https://www.plasticsengineering.org/2026/05/why-recycled-polymers-still-cost-more-than-virgin-resin-011239/
- Categories: Building & Construction, Circular Economy, Education & Training, Flexible Packaging, Food Packaging, Industry, Materials, Medical, Packaging, Polyolefins, Process, Recycling, Recycling, Regulation, Sustainability, Thermoplastics, Trending

Recycled polymers cost 10–20% more than virgin resin, but policy mandates, corporate commitments, and new sorting technologies are reshaping the circular plastics market.

Recycled polymers cost 10–20% more than virgin resin, but policy mandates, corporate commitments, and new sorting technologies are reshaping the circular plastics market. In the U. S. plastics industry, one question keeps coming up at procurement meetings and sustainability summits alike: why does recycled polymer still cost more than virgin resin? The short answer involves tight feedstock supply, complex processing, and growing regulatory demand. The longer answer reveals a market in transition, one in which technical innovation, corporate investment, and government policy are slowly but measurably closing the price gap between recycled and virgin materials. A $127 billion opportunity by 2034: the recycled plastics market is scaling fast, and U. S. manufacturers that secure supply chain positions today will lead the transition away from virgin resin. Courtesy of Precedeence Research. True Cost of Circular Plastics Across most market segments, recycled plastics command a 10 to 20 percent price premium over virgin resin in current markets. In tighter supply conditions, particularly for food-grade recycled PET and polypropylene, that premium can increase even further across regions. Three key forces sustain this premium, including strong competition for limited post-consumer feedstock and the high costs of processing. In addition, multi-stage sorting, washing, and reprocessing infrastructure requires significant capital and operational investment, which increases overall production costs. Finally, the inverse relationship between crude oil prices and virgin resin costs periodically widens the gap during low oil-price environments. Before a single pellet leaves the facility, post-consumer plastic must run a gauntlet of sorting, washing, and compounding...


- Published: 2026-05-11
- Modified: 2026-04-30
- URL: https://www.plasticsengineering.org/2026/05/global-polymer-feedstock-supply-chains-face-rising-disruptions-011233/
- Categories: Business, Energy Generation, Industry, Materials, People, Polyolefins, Regulation, Resins, Trending

Shipping disruptions, geopolitics, and climate policy are reshaping polymer feedstock supply chains and increasing global risk.

Shipping disruptions, geopolitics, and climate policy are reshaping polymer feedstock supply chains and increasing global risk. The polymer industry built its supply chains around large petrochemical hubs and long-distance trade routes. These systems improved efficiency but provided little backup. You can also read: From Crude to Cost: The Oil-Plastic Price Connection. Global Networks Meet Geopolitical Friction Recent disruptions now reveal the risks in that structure. Shipping delays and traffic rerouted through the Red Sea disrupted chemical logistics worldwide. The World Bank reports that regional conflicts forced vessels to avoid major shipping lanes. These disruptions affect feedstocks as much as finished polymers. Ethylene derivatives, liquefied gases, and intermediates rely on specialized maritime infrastructure. When routes change, costs also rise and delivery times expand. Export terminals and carrier fleets also concentrate risk. Navigator Gas recently expanded its Morgans Point terminal for ethylene exports so they can support growing global trade. Such infrastructure increases efficiency but strengthens dependence on a small number of hubs. Feedstock Markets Become More Concentrated Feedstock supply also reflects structural shifts in hydrocarbon production. The United States now dominates global ethane supply due to shale gas production. Data from the U. S. Energy Information Administration show record ethane output and exports recently. American exports now supply more crackers in Europe and Asia. This shift improves access to feedstock in some regions but increases geographic concentration as well. A disruption in one exporting region can affect polymer markets around the world. Companies respond by expanding export infrastructure. Enterprise Products Partners...


- Published: 2026-05-08
- Modified: 2026-04-30
- URL: https://www.plasticsengineering.org/2026/05/redefining-premium-appearance-in-sustainable-plastics-011191/
- Categories: Additives & Colorants, Circular Economy, Decorating & Coatings, Design, Durables, Editor's Choice Technical Paper, Industry, Materials, Packaging, People, Process, Recyclate, Recycling, Recycling, Semi-Finished Products, Sports & Recreation, Sustainability, Trending

How surface variation, subtle discoloration, and visible recycled content are redefining what premium means in plastics.

How surface variation, subtle discoloration, and visible recycled content are redefining what premium means in plastics For decades, brands defined premium as flawless gloss, even color, and zero variation. Sustainability now challenges that idea. Premium design also shapes material choices that complicate recycling. Brands often rely on dark pigments, metallic effects, heavy fillers, and multilayer structures. These features improve shelf impact, but they hinder sorting and reprocessing. You can also read: When Color Becomes Waste. Mechanical recycling creates variation in shade, haze, and surface texture. Contaminants, old additives, and polymer breakdown reduce aesthetic control. Bezeraj et al. describe contamination as a structural constraint rather than a minor processing issue. Design-driven additives and color packages also persist through multiple loops. They can shift melt behavior, distort color, and limit high-end reuse. Marcelino et al. show that recycled PET often has a slight yellowing and color variation, even after advanced filtration. Processors can reduce these defects, but they rarely remove them all. Regulation reinforces the shift. Regulation (EU) 2025/40 requires higher recycled content in packaging formats. The OECD expects circular policies to grow stronger worldwide through 2040. “Premium” can no longer mean identical to virgin resin. Overview of the main recycling pathways for PET, illustrating mechanical recycling through collection, washing, re-extrusion, and pelletizing, as well as alternative approaches such as chemical depolymerization. Courtesy of State-of-the-art of industrial PET mechanical recycling: technologies, impact of contamination and guidelines for decision-making. Engineering Around Aesthetics Unlike traditional carbon black pigments that block NIR sorting systems, NIR-detectable...


- Published: 2026-05-07
- Modified: 2026-04-28
- URL: https://www.plasticsengineering.org/2026/05/pcr-plastics-are-redefining-aesthetic-standards-011186/
- Categories: Circular Economy, Decorating & Coatings, Design, Durables, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, People, Process, Recyclate, Recycling, Recycling, Sustainability, Trending

PCR plastics challenge traditional aesthetics, forcing brands to redefine what is acceptable in color, surface quality, and consumer expectations.

PCR plastics challenge traditional aesthetics, forcing brands to redefine what is acceptable in color, surface quality, and consumer expectations. Virgin plastics set the standard for visual perfection. Recycled content challenges the status quo and forces the industry to redefine what “acceptable” means. For decades, brands demanded tight color control, high clarity, and flawless surfaces to signal quality and protect shelf appeal. Post-consumer recycled (PCR) plastics complicate that expectation. Mechanical recycling leaves visible traces. Sorting errors, thermal history, and low-level contamination affect color, clarity, and surface finish. You can also read: The Complexity of Recyclate. Research confirms these limitations. Bezeraj et al. report persistent discoloration and variability in industrial PET recycling. Polyolefins show similar degradation after multiple processing cycles. A 2024 SPE ANTEC paper links gels and molecular breakdown in recycled polyolefins to visible surface defects. Sensory perception also plays a role. Di Cicco et al. show that consumers associate off-odors with lower product quality, even when performance remains unchanged. Visual and sensory cues together shape acceptance. Standards quantify appearance with precision but stop short of defining acceptability. ISO 11664-4 defines the CIELAB color space, ASTM D2244 quantifies color differences, and ASTM D6290 standardizes pellet color measurement. These tools describe variation; they do not determine what the market will accept. That threshold now depends on commercial alignment across the value chain. Engineering Out Variability Digital watermarks embedded in packaging graphics enable automated sorting systems to identify materials with high precision, improving recycling efficiency without altering conventional printing processes Courtesy of HolyGrail...


- Published: 2026-05-06
- Modified: 2026-04-28
- URL: https://www.plasticsengineering.org/2026/05/reinforcement-learning-for-polymer-design-and-manufacturing-011146/
- Categories: Aerospace, Artificial Intelligence, Automotive & Transportation, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Industry, Industry 4.0, Materials, People, Trending

AI-driven reinforcement learning enables polymer design optimized for performance and manufacturability.

AI-driven reinforcement learning enables polymer design optimized for performance and manufacturability. Artificial intelligence is reshaping polymer science by turning processability and performance into explicit design targets. Through feature reduction and generalization, AI enables models to navigate complex relationships and accelerate materials discovery. You can also read: Rheology in Optimizing Thermoplastic Polymer Performance. From Trial-and-Error to Inverse Design PSPP and Material Science paradigms: Courtesy of Recent Progress of Artificial Intelligence Application in Polymer Materials Designing polymers for high-value applications has traditionally relied on experience-driven synthesis and iterative experimental screening. Compared to metals or ceramics, polymers exhibit highly complex and heterogeneous microstructures, where chemical structure, processing history, and morphology jointly determine final properties. The Processing–Structure–Property–Performance (PSPP) relationship is nonlinear and high-dimensional, making direct correlations difficult to isolate. As a result, conventional workflows depend on repeated cycles of synthesis, processing, testing, and refinement. While computational modeling supports this process, it typically optimizes materials within a narrow design space. Artificial intelligence changes this paradigm. Techniques such as feature extraction and dimensionality reduction enable models to generalize PSPP relationships. Consequently, polymer development shifts from trial-and-error to inverse design, in which target properties guide the generation of new materials. Given performance and processing constraints, models can propose polymer structures likely to satisfy both. Reinforcement Learning in Polymer Design Architecture of reinforcement learning as applied to generative models with the capability to design hypothetical polymer structures possessing specific properties. Courtesy of Benchmarking study of deep generative models for inverse polymer design. Among AI methods, reinforcement learning (RL)...


- Published: 2026-05-05
- Modified: 2026-04-27
- URL: https://www.plasticsengineering.org/2026/05/assessing-the-limits-of-circularity-in-healthcare-plastics-011180/
- Categories: Business, Circular Economy, Industry, Materials, Medical, Polyolefins, Process, Recycling, Recycling, Resins, Sustainability, Thermoplastics, Trending, Vinyl

New research shows polycarbonate from bioprocessing devices can be recycled, challenging circularity limits in healthcare plastics.

New research shows polycarbonate from bioprocessing devices can be recycled, challenging circularity limits in healthcare plastics. Single-use plastics play a central role in modern bioprocessing. Disposable bioreactors, tubing sets, and vessels reduce contamination risks and simplify operations. However, they also lock healthcare into a linear materials model that conflicts with rising sustainability expectations. You can also read: SABIC Makes Polycarbonate From Mixed Recycled Plastics. Until recently, healthcare teams focused circularity efforts on low-risk plastics, such as non-hazardous packaging and bio-based materials. Most stakeholders considered the recovery and reuse of regulated, sterilized devices impractical. However, new research now challenges that assumption. At ANTEC 2026, Pierre Moulinie, Head of Global Technical Marketing for Healthcare in the Engineering Plastics business at Covestro, addressed this issue directly. Drawing on more than 25 years of experience, he emphasized the growing convergence of material science, regulatory requirements, and sustainability targets. Beyond Packaging: Closing the Loop on Devices The study outlines a technical pathway for mechanically recycling polycarbonate from small-scale plastic-based bioreactors. Courtesy of Concept for recycling a small-scale plastic-based bioreactor in a close-loop – Technical approach. Magali Barbaroux and her colleagues conducted experimental work that challenges the assumption that single-use bioprocess equipment must remain linear in material terms. In a study published in the Journal of Cleaner Production, the team demonstrated that polycarbonate (PC) from discarded small-scale bioreactor vessels can be mechanically recycled and reused in cell culture applications without compromising biological performance. The researchers examined widely used laboratory systems, including vessels produced by Sartorius Stedim...


- Published: 2026-05-04
- Modified: 2026-04-27
- URL: https://www.plasticsengineering.org/2026/05/why-your-feeder-choice-is-quietly-undermining-consistency-011175/
- Categories: Auxiliaries, Compounding, Education & Training, Equipment, Extrusion, Feeding Systems, Industry, Injection Molding, Mixing & Blending, Process, Testing & Analysis

Small errors in additive feeding can create disproportionate effects on formulation accuracy, process stability, and final part quality.

Small errors in additive feeding can create disproportionate effects on formulation accuracy, process stability, and final part quality. In plastics processing, engineers typically focus on resin quality, melt temperature, screw design, and mold conditions when they assess consistency. Although these variables are important, they do not fully determine part-to-part uniformity. Additive feeding accuracy also plays a critical role. When a feeder delivers an incorrect amount of colorant, filler, flame retardant, impact modifier, or another additive, the line may continue operating without any obvious warning. However, the formulation has already drifted from its target, and that deviation may later appear as color variation, unstable appearance, scrap, or broader property scatter. This issue becomes particularly important at low letdown ratios or when additives strongly influence final performance. Even a small feeding error can affect stiffness, impact resistance, shrinkage, surface quality, or dimensional stability. In such cases, the feeder is not merely an auxiliary device. It is part of the formulation control system, and its performance directly affects process repeatability. You can also read: Extrusion Troubleshooting – Key Drivers (Part 1 of 3). Feeder Type and Feeding Accuracy Differences among feeder types account for the greater drift sensitivity observed in some operations. Volumetric feeders meter material based on screw speed and an assumed bulk density. They provide a relatively simple and economical metering method when materials exhibit stable and predictable flow behavior. However, they do not verify actual mass throughput in real time. If bulk density changes because the material compacts, fluffs, absorbs...


- Published: 2026-05-01
- Modified: 2026-04-27
- URL: https://www.plasticsengineering.org/2026/05/high-viscosity-photopolymers-transform-additive-manufacturing-011153/
- Categories: 3D Printing/Additive Manufacturing, Aerospace, Automotive & Transportation, Auxiliaries, Business, Design, Elastomers, Energy Generation, Equipment, Industry, Industry 4.0, Materials, Medical, Process, Resins, Thermoplastics, Thermosets, Trending

Advanced printing technologies from CubiCure and Supernova are redefining additive manufacturing with high‑viscosity photopolymer resins.

Advanced printing technologies from CubiCure and Supernova are redefining additive manufacturing with high‑viscosity photopolymer resins. Key Points: High-viscosity photopolymer technologies are pushing additive manufacturing closer to true production-scale performance, helping bridge the gap with traditional molding and forming. Traditional AM photopolymers face key limitations—including weak thermomechanical properties, anisotropy, and high VOC emissions—largely due to the need for low-viscosity formulations that compromise material performance. New approaches using high molecular weight resins and advanced printing methods (like hot lithography and viscous lithography) enable stronger parts, better layer bonding, reduced emissions, and expanded material capabilities—including elastomers, flame-retardant plastics, and multi-material systems. AM aims to match the scale and ubiquity of molding and forming processes. Companies like CubiCure and Supernova are enabling this shift through high‑viscosity photopolymer technology. You can also read: High-Performance 3D Printing with Photosensitive PEEK Ink. AM photopolymer resins have long leveraged existing adhesive and coating chemistry, accelerating resin development. However, despite resin development and hardware advances, photopolymer performance has often lagged behind that of traditional manufacturing materials. As a result, many AM photopolymers still fall short of thermoplastic standards, limiting end‑use adoption. AM Photopolymer Limitations Common AM photopolymer shortcomings include weak thermomechanical performance, severe anisotropy, and higher VOC emissions, raising product and chemical safety concerns. A key driver of these issues is the need to drastically reduce print viscosity, or the measure of resin flow during the print process. This trade secret and hardware-specific process is critical to ensure part geometry, throughput, and ultimate end use. High-viscosity resins tend to...


- Published: 2026-04-30
- Modified: 2026-04-24
- URL: https://www.plasticsengineering.org/2026/04/upcycling-polyolefins-into-jet-fuel-components-011138/
- Categories: Aerospace, Business, Circular Economy, Education & Training, Energy Generation, Industry, Materials, People, Polyethylene, Polyolefins, Recycling, Resins, Sustainability, Trending
- Tags: Carbon Footprint, plastic waste, Polyolefins, pyrolysis

A breakthrough method transforms HDPE waste into jet fuel components, boosting yield, quality, and sustainability.

A breakthrough method transforms HDPE waste into jet fuel components, boosting yield, quality, and sustainability. Thermal conversion of plastic waste into fuel can replace fossil fuels while simultaneously mitigating environmental pollution. When using pyrolysis for polyolefins, catalysts can significantly reduce the energy required for thermal cracking. Zeolites are particularly beneficial for the production of hydrocarbons in the jet fuel range. You can also read: Zeolites: A Mineral’s Role in Upcycling Plastic Waste. Novel Method Converting HDPE into Jet Fuel This method uses Fe/Beta catalysts, synthesized by impregnating Beta zeolites with a SiO2:Al2O3 ratio of 30. Decalin, a solvent and direct fuel blend component, reacts with Fe-zeolite catalysts during HDPE cracking. This produces oil with a high heating value (HHV) with significant potential as a jet fuel component. Researchers developed a methodology to obtain 84. 0 wt% oil from HDPE. Figure courtesy of Efficient polyolefin plastic upcycling into jet fuel components over a Fe/Beta catalyst in decalin. Catalyst Optimization During development of this methodology, researchers evaluated a variety of catalysts with different Fe loadings. A Fe-loaded catalyst with a nominal 10 wt% Fe (10Fe/Beta) delivered optimal performance. Using this catalyst, researchers obtained an oil yield of 84. 0 wt% under 300 °C for 90 minutes. This outperformed a commercial Beta zeolite catalyst alone, with an oil yield of 74. 2 wt% primarily composed of gasoline-range hydrocarbons. Using the 10Fe/Beta catalyst, the resultant oil’s carbon number distribution was mainly concentrated in C8-C16. These carbon numbers indicate that the resulting product is suitable...


- Published: 2026-04-29
- Modified: 2026-04-24
- URL: https://www.plasticsengineering.org/2026/04/renewable-functional-coatings-for-advanced-applications-011134/
- Categories: Automotive & Transportation, Bioplastics, Circular Economy, Decorating & Coatings, Design, Education & Training, Elastomers, Electrical & Electronics, Energy Generation, Industry, Materials, People, Process, Regulation, Resins, Sustainability, Thermoplastics, Trending
- Tags: Polylactic Acid

Coatings derived from renewable resources meet performance requirements while addressing environmental concerns.

Coatings derived from renewable resources meet performance requirements while addressing environmental concerns. Functional coatings protect plastic parts while enhancing their performance and applications. These coatings provide benefits such as abrasion or fire resistance, as well as self-healing, anticorrosive, and antibacterial properties. By developing and using functional coatings made from renewable resources, researchers and manufacturers can lessen their carbon footprint. Over recent years, advancements in renewable functional coatings have shown significant innovation in performance and sustainability. You can also read: Advances in Sustainable Polymer-Based Anticorrosive Coatings. Renewable sources for functional coatings include bio-, mineral-, and chemical-based materials. Figure courtesy of Advancing renewable functional coatings: sustainable solutions for modern material challenges. Bio-Based Resources for Functional Coatings A wide range of sources provides functional coatings, each offering unique benefits and use cases. Bio-based polymers, such as polylactic acid (PLA), are both renewable and biodegradable. These are particularly beneficial for coatings for biodegradable packaging, textiles, and biomedical applications. Their synthesis is achievable through polymerization, chemical modification, or blending them with other materials. Recent innovations have developed bio-based polymer coatings that can extend the shelf life of fruits. Advances in asphalt additives and shape memory polymers also leverage this technology, reducing dependence on fossil-fuel-based coatings. Rosin: Cost Effective Functional Coatings from Tree Resin Rosin, a resin produced by trees, is another example of a renewable source of functional coatings. It offers corrosion resistance, thermal stability, increased hardness, as well as visual enhancements from gloss and color. It is a low-cost material and thus also has...


- Published: 2026-04-28
- Modified: 2026-04-24
- URL: https://www.plasticsengineering.org/2026/04/ikv-colloquium-2026-the-journey-of-research-and-industry-010989/
- Categories: Business, Circular Economy, Design, Industry, Resins, Sustainability, Trending
- Tags: additive manufacturing, Circular Economy, Extrusion

IKV Kolloquium 2026 shows how circularity, AI, and process excellence converge to accelerate a profitable, low‑impact plastics value chain.

IKV Kolloquium 2026 shows how circularity, AI, and process excellence converge to accelerate a profitable, low‑impact plastics value chain. The 33rd International Colloquium on Plastics Technology in Aachen showed rapid progress toward circular plastics. Plastics can advance in circularity while remaining profitable. AI and smarter process control accelerate this transition. On 4–5 March 2026, IKV welcomed the plastics community to Eurogress Aachen. The event featured five plenaries, sixteen sessions, and an industry exhibition. Attendees could build a customised agenda, from recyclates to laser welding. The institute’s model relies on industry sponsorship and joint research projects. Pilot‑scale labs keep developments grounded in real manufacturing conditions. This approach accelerates technology transfer into industrial practice. You can also read: Sustainability Takes the Spotlight at ANTEC®2025 Why IKV Still Matters Since 1950, IKV has acted as a bridge between academia and the shop floor. Today, the strategy focuses on circular economy, digitalisation, lightweighting, and additive manufacturing. These themes also shaped the 2026 sessions and live demonstrations. The sponsors’ association includes hundreds of companies. Their support ensures trial lines and materials reflect real production constraints. This approach prevents idealised lab conditions from distorting results. Highlights From Each Main Session Additivation, de‑inking, coating: IKV showed why classic mechanical recycling now needs de‑inking and PECVD barrier layers to deliver packaging‑grade recyclates and hit EU 2030 targets. In practice, this closes the gap between post‑consumer films and contact‑sensitive uses. Evonik’s contribution on additive routes demonstrated how suppliers tune stabilisation and rheology for circular streams. Circular products through foam...


- Published: 2026-04-27
- Modified: 2026-04-27
- URL: https://www.plasticsengineering.org/2026/04/nanocomposite-films-from-car-bumper-waste-011041/
- Categories: Automotive & Transportation, Bioplastics, Circular Economy, Composites, Industry, Materials, Polyolefins, Process, Recyclate, Recycling, Sustainability, Thermoforming, Thermosets

A novel method recycles linear low-density polyethylene (LLDPE) with car bumper waste into nanocomposite films.

A novel method recycles linear low-density polyethylene (LLDPE) with car bumper waste into nanocomposite films. Car bumpers are typically composed of thermoplastic polyolefin elastomers (TPOs). While front bumpers are usually made of pure TPO, manufacturers often use talc-filled TPO for rear bumpers to lower production costs. Coatings and talc fillers make recycling used plastic bumpers challenging. You can also read: Boosting Biodegradable Packaging with PLA/Nanoclay/ZnO Films. Additionally, polyolefins exhibit reduced performance across a variety of properties when recycled. Adding clays to form polymer/clay nanocomposites can improve many such properties. Recycling to Create Plastic Mulch Films Recycled polyolefin/clay nanocomposites show promise for applications in plastic mulch films, particularly for fumigation mulch. For instance, these films improve gas-barrier properties, thereby trapping volatile pesticides in the soil. In a recent study, researchers developed a nanocomposite film comprising waste bumpers, compatibilizers, fillers, and virgin LLDPE. Furthermore, they enhanced these films with nanoclay fillers compatibilized with polyethylene grafted maleic anhydride (PE-g-MEH). Ultimately, this study intended to develop a cost-effective method for producing plastic mulch films while, in tandem, creating a new recycling pathway for discarded car bumpers. Analyzing Waste Bumpers Researchers used Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), and thermogravimetric analysis (TGA) to characterize the waste bumpers. The composition of the bumpers included polypropylene, polypropylene-based elastomer, polyethylene, acrylic paint, and talc. Using TGA, researchers analyzed the thermal stability and compositional characteristics of the waste material. Results indicated that the material contained 5% CaCO, 9% talc residue, and 84% organic polypropylene. Adding Nanoclay...


- Published: 2026-04-24
- Modified: 2026-04-08
- URL: https://www.plasticsengineering.org/2026/04/emerging-markets-for-polyolefins-in-the-solar-industry-011128/
- Categories: Education & Training, Electrical & Electronics, Energy Generation, Equipment, Extrusion, Film, Industry, Materials, Polyethylene, Polyolefins, Polypropylene, Process, Resins, Semi-Finished Products, Testing & Analysis, Trending, Vinyl

Polyolefins are increasingly replacing conventional materials as encapsulant films in photovoltaic solar panels.

Polyolefins are increasingly replacing conventional materials as encapsulant films in photovoltaic solar panels. Polyolefins have gained significant market share as encapsulants for photovoltaic modules. Since the 1980s, chemically crosslinked EVA has been the most common material for this purpose. EVA provides good durability and performance but requires chemical crosslinking for thermos-mechanical stability. Thus, it has a limited shelf life, an intensive lamination process, and can form acetic acid during degradation, leading to corrosion. The world market share for EVA-based encapsulants has been steadily dropping in favor of polyolefin and EVA/polyolefin elastomer (POE) mixtures. You can also read: Can Plastic Solar Cells Finally Go Mainstream? Market predictions show polyolefin encapsulants continuing to gain popularity for solar cells. Courtesy of What Is a Polyolefin? A Critical Overview of Ethylene Copolymers Used as Solar Photovoltaic Module Encapsulants. How Polyolefins Gained a Stronghold in Encapsulants In the mid-1990s, researchers began investigating polyolefins as alternatives to EVA encapsulants. This research showed that polyolefins may avoid adhesion failure while providing better ultraviolet (UV) stability. Thus, these materials presented a suitable alternative to EVA if not used at high operating temperatures. In the following years, research continued to expand the use of polyolefins for encapsulation. In 2008, for example, The Dow Chemical Company developed functionalized polyolefins for encapsulation. These materials reduced moisture permeation, did not require curing, and did not produce acetic acid. They had a lower density than EVA and better adhesion to glass. More recent research has developed innovative polyolefin encapsulants, cross-linked POEs, and thermoplastic...


- Published: 2026-04-23
- Modified: 2026-04-08
- URL: https://www.plasticsengineering.org/2026/04/conductive-polymers-revolutionize-fuel-cell-plates-011057/
- Categories: Circular Economy, Composites, Editor's Choice Technical Paper, Electric Vehicles, Electrical & Electronics, Energy Generation, Film, Industry, Materials, People, Polyolefins, Polypropylene, Process, Resins, Sustainability, Testing & Analysis, Thermoforming, Thermoplastics, Trending
- Tags: Conductive polymers, Injection Molding

Engineers optimize conductive polymer composites for fuel cell bipolar plates, achieving low weight and high conductivity for advanced energy systems.

Engineers optimize conductive polymer composites for fuel cell bipolar plates, achieving low weight and high conductivity for advanced energy systems. Engineers face severe weight and corrosion bottlenecks when designing traditional metallic bipolar plates for Proton Exchange Membrane Fuel Cells (PEMFCs). To overcome these limitations, material scientists leverage high-aspect-ratio nanoscale fillers to construct a conductive percolation network within polymer matrices, enabling robust, lightweight, and corrosion-resistant power generation. You can also read: Composite Polymer Electrolytes: Transforming Energy Storage. Engineering the Conductive Percolation Network Engineers achieve electrical conductivity by insulating polymers by forcing filler particles into physical contact. Nanoscale fillers, such as multiwalled carbon nanotubes (MWCNTs), extend to interlink larger graphite particles and chopped carbon fibers (CCFs). This strategic dispersion reduces resistance to electron transport, facilitating efficient electron hopping and tunneling effects across the matrix. Polypropylene (PP) matrices reach the initial percolation threshold at 50 wt. % filler content, but engineers require loading levels up to 80 wt. % to sustain the heavy currents demanded by bipolar plates. Simultaneously, the base polymer resin firmly bonds to these carbon fillers, minimizing voids. This tight encapsulation ensures the composite maintains a strict gas permeability rate below 1 × 10⁻⁵ cm³/(s·cm²) ⁻¹ under hydrogen atmospheres. By preventing gas crossover, designers guarantee safe fuel cell operation over extended lifecycles. Schematic diagram of PEM fuel cell. Courtesy of Optimization of Filler Compositions of Electrically Conductive Polypropylene Composites for the Manufacturing of Bipolar Plates. Performance Metrics and Material Viability To determine the optimal material for specific power demands, developers...


- Published: 2026-04-22
- Modified: 2026-04-06
- URL: https://www.plasticsengineering.org/2026/04/beyond-flaps-how-composite-skins-enable-morphing-wing-design-010950/
- Categories: Aerospace, Business, Composites, Compounding, Design, Education & Training, Elastomers, Extrusion, Hybrid Manufacturing, Industry, Injection Molding, Materials, Mixing & Blending, Process, Regulation, Resins, Semi-Finished Products, Strategy, Sustainability, Thermoforming, Thermosets, Trending

Morphing technology is key to green aviation, enabling real-time adaptation that significantly improves aerodynamic efficiency.

Morphing technology is key to green aviation, enabling real-time adaptation that significantly improves aerodynamic efficiency. Traditional aircraft design optimizes performance for a single phase of flight. This phase is cruise, and aircraft use discrete surfaces such as flaps and slats for other phases or conditions. The concept of morphing refers to a structure's ability to undergo continuous geometric changes. In this way, the mission profile can be optimized at all stages. In short, advanced polymeric and composite materials are the foundation upon which engineers are building the more efficient NGA. You can also read: Polymers Take Flight: How Plastics Are Powering eVTOL Design. Polymeric Materials and Composites as Technical Enablers Engineers can combine structural properties with adaptive flexibility to break away from the limitations of traditional designs and materials. Aero-structural researchers are currently working with the following types of materials for structures and skins. Shape Memory Polymers (SMP) and Composites (SMPC): These materials can remember their original shape and return to it after the deforming effect of thermal or electrical stimuli. This makes SMPCs particularly attractive for wing skin applications with variable stiffness. Carbon Fiber Reinforced Polymers (CFRP) and Nanocomposites (PNC): CFRPs offer a high strength-to-weight ratio and directional properties that engineers can exploit through aeroelastic tailoring. This directionality allows for the induction of preset couplings between bending and torsion. Additionally, the use of polymer nanocomposites (PNC) promises further increases in structural stiffness and strength. Elastomers for Flexible Skins & Internal Structure: The surface must remain smooth and continuous even...


- Published: 2026-04-21
- Modified: 2026-04-03
- URL: https://www.plasticsengineering.org/2026/04/flame-resistant-polymers-for-space-safety-and-aerospace-use-011162/
- Categories: Additives & Colorants, Aerospace, Industry, Materials, Process, Regulation, Testing & Analysis, Trending

NASA advances flame-resistant polymers to improve safety in microgravity and high-oxygen aerospace environments.

NASA advances flame-resistant polymers to improve safety in microgravity and high-oxygen aerospace environments. Understanding flammability on Earth is already complex; however, space introduces additional challenges, including microgravity and oxygen-enriched, pressurized environments. These conditions alter flame behavior, heat transfer, and material response. As a result, NASA and its partners have developed specialized testing methods and polymer systems to control fire risks in orbit and beyond. You can also read: Aerospace Plastics Market: Lighter, Stronger, and Poised for Takeoff. From spacesuits to the International Space Station (ISS), every electrical system, structural component, and cabin material undergoes rigorous flammability evaluation. Polymers, in particular, present unique challenges due to their tendency to ignite, sustain combustion, and release heat. Consequently, NASA engineers focus on understanding ignition thresholds, flame propagation, and heat release behavior to ensure mission safety. Evaluating Flammability in Space NASA provides open access to its Technical Standards System (TSS). Courtesy of NASA. To support aerospace development, NASA provides open access to its Technical Standards System (TSS), which standardizes materials testing and qualification procedures. Two key standards define flammability requirements: NASA-STD-6001: Flammability, offgassing, and compatibility testing NASA-STD-6016: Materials and processes requirements for spacecraft Together, these standards establish a framework for evaluating fire behavior under space-relevant conditions, including reduced gravity and elevated oxygen concentrations. Although originally developed for metals and ceramics, they now guide the qualification of advanced polymer systems increasingly used in long-duration missions. As polymer usage expands in aerospace applications, testing methods must also evolve. This has driven the development of new experimental...


- Published: 2026-04-20
- Modified: 2026-04-03
- URL: https://www.plasticsengineering.org/2026/04/real-time-melt-monitoring-in-extrusion-and-injection-molding-011167/
- Categories: Education & Training, Equipment, Extrusion, Industry, Injection Molding, Process, Sensors

Inline rheology and spectroscopy enable real-time melt monitoring, improving quality control in extrusion and injection molding.

Inline rheology and spectroscopy enable real-time melt monitoring, improving quality control in extrusion and injection molding. In extrusion and molding, product quality depends on the condition of the polymer melt during shaping. Changes in viscosity, composition, temperature history, moisture, or contamination can push the process outside its validated window. The result may include dimensional variation, surface defects, color shifts, or changes in mechanical performance. Many of these problems begin upstream, but processors often detect them only during offline inspection or downstream testing. This gap has increased interest in inline melt monitoring. Two methods stand out: inline rheology and near-infrared or infrared spectroscopy. Rheological indicators track changes in flow behavior. Spectroscopic methods detect changes in composition and molecular structure. Used together, these tools give processors a broader view of melt quality during production and help identify deviations before defects spread. You can also read: At ANTEC 2026: Process-Specific Rheology for Advanced Material Selection Inline Rheology as a Process Stability Indicator A dedicated inline viscometer is installed perpendicular to the extruder barrel, enabling direct, real-time measurement of polymer melt viscosity between the screw and the die. Courtesy of Rheonics. Inline rheology in industry is evolving rapidly. While many plants still rely on tracking simpler viscosity proxies derived from standard process data, such as melt pressure, temperature, screw speed, or throughput, there is an increasing trend toward deploying dedicated inline instrumentation. These specialized instruments, such as vibrational viscometers or slip-stream rheometers, operate directly in the melt stream and provide sensitive, real-time data that...


- Published: 2026-04-17
- Modified: 2026-04-02
- URL: https://www.plasticsengineering.org/2026/04/conveying-pcr-reducing-fines-angel-hair-and-scrap-011052/
- Categories: Automation, Auxiliaries, Editor's Choice Technical Paper, Equipment, Feeding Systems, Industry, Materials, People, Process, Recyclate, Resins
- Tags: Recycled plastics

Pneumatic conveying can support efficient PCR processing, but only when system design and operating conditions protect pellet integrity and maintain stable separation.

Pneumatic conveying can support efficient PCR processing, but only when system design and operating conditions protect pellet integrity and maintain stable separation. Pneumatic conveying can transition from routine material transfer to a significant contamination source when operating conditions and line geometry do not align with resin behavior. Dust and polymer stringing can enter hoppers and dryers, increase filter loading, destabilize feeding, and elevate the risk of cosmetic defects and scrap. Effective control depends on core design and operating parameters. Gas velocity, bend geometry, pipeline surface condition, and conveying distance govern the impact and friction mechanisms that generate fines and fibrils. Receiver configuration then dictates whether separation captures these byproducts or allows downstream carryover. Routine monitoring, including ΔP trending, filter loading rate, and periodic dust-mass measurements, provides early warning and supports stable performance. You can also read: The Complexity of Recyclate. Why PCR Pellets Create More Fines and Angel Hair Fines and angel hair generated during pellet conveying can compromise separation efficiency and downstream processing stability. Courtesy of Azo. Processors now run post-consumer recycled (PCR) resins at production scale, but pellet morphology and cleanliness often differ from virgin materials and increase vulnerability to pneumatic-transport damage. Broader distributions in pellet size, shape, and mechanical integrity, plus rough surfaces and edge defects from reprocessing, increase inter-pellet and pellet-wall collisions and raise impact severity. Trace hard contaminants (grit, mineral fillers, metal/glass fragments) increase abrasion, especially at elbows, valves, and other high-turbulence zones, which accelerates fines generation and downstream quality defects. Elevated sliding friction and...


- Published: 2026-04-16
- Modified: 2026-04-02
- URL: https://www.plasticsengineering.org/2026/04/artificial-rattan-furniture-from-polyal-011037/
- Categories: Circular Economy, Design, Durables, Extrusion, Industry, Materials, Polyethylene, Polyolefins, Process, Recyclate, Recycling, Recycling, Resins, Sports & Recreation, Sustainability, Thermoplastics, Vinyl
- Tags: Circular Economy

Recycled PolyAl beverage cartons are finding new life as design-forward furniture.

Recycled PolyAl beverage cartons are finding new life as design-forward furniture. Researchers are finding innovative ways to upcycle plastic waste into valuable products across various sectors. One example is artificial rattan: a durable material used for furniture. Designed to mimic natural rattan, artificial rattan is typically comprised of polyethylene (PE), high-density polyethylene (HDPE), and polyvinyl chloride (PVC). As a sustainable alternative, researchers developed an artificial rattan from “PolyAl”, comprised of PE film and aluminum layers. PolyAl, commonly used for beverage carton packaging, is difficult to recycle. Through thoughtful and creative designs, such as artificial rattan, this material can be converted into useful new products. You can also read: Turning Coffee Waste into 3D Printed Furniture. End-of-Life Plastics as a Material Source To create artificial rattan, researchers sourced PolyAl from used beverage cartons. They processed the plastic film and aluminum layers of the PolyAl into plastic pellets. Researchers also assessed recycled plastics from plastic bag manufacturing scraps, discarded bottle caps, and food packaging scraps for the composite. These comprised linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), and polypropylene (PP), respectively. Natural fiber from discarded bamboo chopsticks from restaurants served as a natural reinforcement for the material. Preparing the Artificial Rattan Material Researchers mixed the PolyAl with recycled LLDPE, HDPE, and PP, then compounded it at 190 °C using a twin-screw extruder. The optimal blend of PolyAl and recycled plastic was 30/70 PolyAl/PP. Adding more than 30 wt% PolyAl showed only minor improvements to stiffness while subsequently decreasing impact strength. Thus, researchers...


- Published: 2026-04-15
- Modified: 2026-04-02
- URL: https://www.plasticsengineering.org/2026/04/advancing-sustainable-printed-electronics-011032/
- Categories: Bioplastics, Business, Circular Economy, Design, Electrical & Electronics, Industry, Materials, Polyolefins, Resins, Sustainability, Thermoplastics, Trending
- Tags: additive manufacturing, Biopolymers, Conductive polymers

Advances in biobased substrates for printed devices show potential to improve sustainability in electronics.

Advances in biobased substrates for printed devices show potential to improve sustainability in electronics. Electronic device printing is a rapidly developing technology. Subsequently, recent advances in plastics engineering show promise for increased sustainability for these printed devices. As printed electronics become more commercialized, manufacturers using fossil-based printing substrates may intensify environmental concerns. Thus, researchers are investigating the integration of biopolymers in printed devices. You can also read: Additive Manufacturing of Conductive Polymer Electronics. As technology improves, printed electronic systems can continue to better align with sustainability goals. Figure courtesy of Biobased Polymers in Printed Electronics: From Renewable Resources to Functional Devices. Performance-Oriented Design Printed electronics have high performance demands. When designing biobased polymers for this application, modification strategies can enhance their robustness. Blending biopolymers with nanofillers, chemical-crosslinking, plasticization, and plasma treatments can result in more effective materials. Copolymerization with conductive additives also has unique potential in devices such as sensors and energy storage systems. Contact and non-contact-based printing, as well as additive manufacturing, are methods of fabricating printed electronic devices. Within contact-based printing, manufacturers employ various techniques, such as roll-to-roll and screen printing. Inkjet and aerosol jet printing are examples of non-contact-based methods. Each method requires special considerations for materials when transitioning to bio-based polymers. Research continues to optimize biopolymers for each of these use cases so they can better integrate into industrial printing methods. Researchers expect formulation and processing technique advancements to further improve their mechanical, thermal, and chemical robustness. Substrates: Solid Supporting Materials in Electronic Devices Electronic device...


- Published: 2026-04-15
- Modified: 2026-04-08
- URL: https://www.plasticsengineering.org/2026/04/antec-2026-rheology-understanding-leads-to-competitiveness-010797/
- Categories: Editor's Choice Technical Paper, Elastomers, Equipment, Industry, Injection Molding, Materials, Trending
- Tags: ANTEC 2026, Compression Molding, Cycle Time Reduction, Injection Molding, Manufacturing Efficiency, Plastics industry, polymer processing, quality control, Simulation, Thermoplastics

ANTEC 2026 and the SPE Applied Rheology Chapter brought top innovators to Pittsburgh from March 9–12 of technical progress in plastics.

ANTEC 2026 and the SPE Applied Rheology Chapter bring top innovators to Pittsburgh from March 9–12 to discuss technical progress in plastics. The event blends scientific rigor with real‑world process improvements, giving attendees the tools they need to elevate productivity, reduce waste, and deepen understanding of materials and processes. You can also read: Rheometer: 5 Keys for Optimal Selection. Why the Plastics Industry and Academia Attended ANTEC 2026 ANTEC 2026 delivered a rare concentration of peer‑reviewed research, applied engineering solutions, and expert‑led sessions. Throughout the event, participants explored topics ranging from injection molding and extrusion to rheology, simulation, sustainability, and advanced materials. In addition, the program encouraged attendees to connect these disciplines and understand how they shaped modern plastics processing. As a result, engineers walked away with practical insights that improved processing windows, strengthened quality control, and guided better material selection. Meanwhile, academics gained valuable exposure to real industrial challenges, which ultimately helped them align research priorities with the evolving needs of the plastics industry. ANTEC 2026 brought together engineers and researchers to share advances in rheology, simulation, and plastics processing. One standout presentation, “Viscoelastic Constitutive Modeling for Flow Simulation in Injection and Compression Molding Based on Log Conformation Methods,” took place on March 11 from 1:30 to 2:00 PM. Lutz Pauli from SIGMA Plastics Services Inc. introduced cutting-edge modeling work that significantly increased the accuracy of flow simulations. He showed how engineers could better predict elastic stresses, orientation states, and deformation behavior during molding. His method broke long-standing numerical...


- Published: 2026-04-14
- Modified: 2026-04-02
- URL: https://www.plasticsengineering.org/2026/04/how-to-test-for-chemical-resistance-in-plastic-components-010963/
- Categories: Automotive & Transportation, Building & Construction, Durables, Electrical & Electronics, Industry, Injection Molding, Materials, Packaging, Polycarbonate, Process, Resins, Testing & Analysis, Thermoplastics
- Tags: Compression Molding, Injection Molding, Material Science, material selection, polymer degradation, quality control

Some applications require evaluating materials or parts under chemical stress. A practical insight provides tips for implementing standard or tailored testing to ensure part performance.

Some applications require evaluating materials or parts under chemical stress. A practical insight provides tips for implementing standard or tailored testing to ensure part performance. Chemical resistance is one of the polymer properties you should be looking for when getting in contact with solvents, varnishes, or other chemicals. It essentially determines a plastic component's ability to withstand chemical attack without changes in weight, appearance, or mechanical properties, such as hardness. You can also read: Direct Compounding Injection Molding: Cost-Efficient Expertise. Defining Chemical Resistance: Moving Beyond Trial and Error During my consultancy work, clients often ask me to identify the cause of part failures. I frequently find that many plastic users do not understand the consequences of chemical attack. Most people learn this lesson the hard way: through failure. Furthermore, companies typically omit chemical resistance or Environmental Stress Cracking Resistance (ESCR) from their material selection process. ESCR represents the combined effect of mechanical and chemical damage on a component over time. Consequently, failure rarely stems from a single cause; instead, a combination of factors usually triggers the breakdown. When selecting a material, we must always ask: How long will this part remain in operation? Also, what substances will it come into contact with? Once we answer these questions, we can determine which in-house test methods will best ensure part quality. Chemical damage may arise in the form of cracking, degradation, weight gain or mechanical failure. This image shows a time-lapse of a PC sample showing environmental stress cracking. Courtesy of Madison...


- Published: 2026-04-13
- Modified: 2026-04-01
- URL: https://www.plasticsengineering.org/2026/04/upcycling-pet-through-artificial-photosynthesis-010940/
- Categories: Business, Circular Economy, Editor's Choice Technical Paper, Education & Training, Food Packaging, Industry, Materials, Packaging, People, PET, Process, Recyclate, Recycling, Recycling, Resins, Strategy, Sustainability, Trending
- Tags: Material Science, Sustainability

High-performance photocatalysts can upcycle post-consumer polyester under mild conditions.

High-performance photocatalysts can upcycle post-consumer polyester under mild conditions. Photocatalysis is an option for upcycling plastic waste under ambient conditions. Using solar energy, photocatalysts such as CdS, TiO2, and g-C3N4 induce redox reactions in plastic. Through the partial oxidation of plastics, these photocatalysts recover plastic’s carbon resources. This method offers a cost-effective alternative to traditional waste management, reducing carbon emissions while valorizing waste into high-value compounds. You can also read: Bioinspired Hydrogels in Clean Energy and Hydrogen Generation. Process of Photocatalysis During photocatalysis, solar energy generates electron-hole pairs. Then, charge carriers migrate from the bulk to the photocatalyst surface. Redox reactions then occur on the photocatalyst’s surface. This process generates electrons, which can be used for water splitting or CO2 reduction to produce fuels. In turn, the resulting electron holes have applications in plastic valorization. Photocatalysis has applications in polyester upcycling integrated with water splitting, valorization, and CO2 reduction, as well as in organonitrogen synthesis. Figure courtesy of Beyond mechanical recycling: artificial photosynthesis enables upcycling of polyester plastic into valuable chemicals. Designing for Plastic Conversion When designing photocatalysts, modifying the redox potential can enhance their effectiveness. Methods such as doping engineering and heterojunction constructions can achieve this. Element doping: This process introduces heteroatoms into the lattice of photocatalysts. This modifies the redox capacity of the photocatalyst by inducing changes in its energy band. Previous research investigated Cu doping of BiOBr, a photocatalyst, through a one-pot solvothermal method. This narrowed the band gap of BiOBr while tuning its redox capacity. Heterojunction...


- Published: 2026-04-10
- Modified: 2026-04-01
- URL: https://www.plasticsengineering.org/2026/04/in-vivo-plastic-waste-upcycling-010935/
- Categories: Artificial Intelligence, Business, Circular Economy, Education & Training, Equipment, Feeding Systems, Flexible Packaging, Food Packaging, Industry, Industry 4.0, Materials, Packaging, Polyolefins, Process, Recycling, Recycling, Resins, Software, Sustainability, Thermoplastics, Trending
- Tags: Circular Economy, Microplastics, PET recycling

Advancements in biotechnology highlight how engineered microbial catalysts can recycle plastic waste in vivo.

Advancements in biotechnology highlight how engineered microbial catalysts can recycle plastic waste in vivo. Most current enzymatic approaches to managing plastic waste occur in vitro. These approaches include using enzymes to cleave plastic polymers, thereby releasing constituent monomers for repolymerization. Other bio-based approaches upcycle plastic waste into value-added compounds or use it as a carbon source for microorganisms. Novel research seeks to take this process in vivo. This entails using whole-cell microbial catalysts that feed directly on plastic waste, which could help address environmental challenges. You can also read: Bio-Based Media for Micro- and Nanoplastics Removal. Advanced bio-based plastic waste management systems offer increased remediation potential but require further refinement. Figure courtesy of Engineering whole-cell catalysts to use plastic waste as a feedstock. Whole-Cell Catalysts: Technical Challenges Though whole-cell catalysts show promise for environmental remediation, challenges for researchers remain. Highly crystalline, tightly-packed polymer chains, for example, inhibit enzymatic hydrolysis. For polyethylene terephthalate (PET), this inhibition occurs when crystallinity exceeds 30%, which is common in post-consumer waste. Pretreatment methods, such as extrusion and mechanical shear, cryomilling, and solvent exposure can reduce crystallinity to overcome this. Microplastics, however, are often highly crystalline. Conventional pretreatment strategies are not sufficient for microplastic treatment. Novel strategies, such as engineered microbes that secrete softening agents, may overcome this limitation. Designing pretreatments suitable for microplastics can enhance the effectiveness of bio-based waste treatment. Figure courtesy of Engineering whole-cell catalysts to use plastic waste as a feedstock. Protein Engineering Machine learning and artificial intelligence have contributed to recent...


- Published: 2026-04-09
- Modified: 2026-04-09
- URL: https://www.plasticsengineering.org/2026/04/flexforum-2026-brings-flexible-packaging-leaders-to-fort-myers-011346/
- Categories: Business, Circular Economy, Education & Training, Flexible Packaging, Industry, Materials, Packaging, Polyethylene, Polyolefins, Process, Recycling, Regulation, Resins, SPE News, Sustainability, Trending
- Tags: EPR, Extended producer responsibility

Get a preview of FlexForum 2026, where flexible packaging professionals will explore regulation, circularity, innovation, and market trends.

Get a preview of FlexForum 2026, where flexible packaging professionals will explore regulation, circularity, innovation, and market trends. FlexForum 2026 brings the flexible packaging industry to Fort Myers, Florida, from May 4–6 for three days of discussion and networking. The event brings together converters, suppliers, manufacturers, and engineers to discuss focused conversations across the value chain. You can also read: FlexForum 2026: Key Policy Shifts in Flexible Packaging. Where the Market Is Heading This track explores the market forces shaping flexible packaging, including changing demand, shifting customer expectations, and increasing pressure on margins. Perc Pineda, PhD, Chief Economist of Plastics Industry Association (PLASTICS), will show the Economic Outlook 2026: Forces Shaping the Future of Flexible Plastics. Drawing on economic data and industry context, attendees will gain a clearer perspective on current conditions and the factors likely to influence flexible plastic packaging in the year ahead. As a result, attendees can better understand how producers are balancing performance, cost, and innovation in a highly competitive environment. In addition. Rules Reshaping the Industry This track focuses on the policy changes affecting packaging design, material selection, labeling, and broader compliance planning across the industry. The talk Policy Landscape: What's Coming for Flexible Packaging may address extended producer responsibility, recycled content requirements, and other regulations that continue gaining momentum. Because these issues now directly influence business decisions, this part of the program should attract strong interest from attendees. The Push Toward Circularity Sustainability remains central to the event, as companies continue working toward recyclability,...


- Published: 2026-04-09
- Modified: 2026-04-01
- URL: https://www.plasticsengineering.org/2026/04/recyqmeter-quantifying-recycled-plastic-quality-010917/
- Categories: Artificial Intelligence, Equipment, Industry, Industry 4.0, Materials, Process, Recyclate, Recycling, Sensors, Software, Sustainability, Trending
- Tags: Circular Economy, LCA, Material Science, plastic recycling, polymer processing

A newly developed, open-access tool helps plastic recyclers pinpoint appropriate market applications.

A newly developed, open-access tool helps plastic recyclers pinpoint appropriate market applications. Recycling methodology and waste composition can influence the quality of recycled plastics. Many plastic parts require specific grades or amounts of virgin plastic to maintain quality in their specific application. Additionally, regulations may require manufacturers to incorporate certain amounts of recycled plastic into new materials. To help stakeholders in academia and industry more easily assess the quality of recycled plastics, researchers have developed RecyQMeter. You can also read: Flexible Packaging: Collective Testing Delivers New Insight into Real-World Recycling RecyQMeter is a tool that analyzes recycled compounds, or recyclates, to evaluate their useability for manufacturing. This tool enables users to easily leverage quality quantification frameworks based in existing scientific literature. It standardizes calculations based on the Quality Model for Recycled Plastic (QMRP) and Recycling Quality (RQ) models. This provides users with consistent data that can help them choose the best sources of recycled plastic. QMRP and RQ: A Framework for Calculating Quality The QMRP and RQ are two methods for quantifying recycled plastic quality. The QMRP model compares the properties of recycled plastic to ideal values using a non-linear function. If one of the quality properties evaluates to zero, the overall quality will also be zero. The RQ model defines the values RQproc (quality during manufacture) and RQmech (quality of the final material). This model outputs a value score between zero and one, with a score closer to one indicating higher quality. The use of different functions can influence...


- Published: 2026-04-08
- Modified: 2026-04-01
- URL: https://www.plasticsengineering.org/2026/04/recycled-carbon-fiber-from-automotive-waste-010930/
- Categories: Automotive & Transportation, Business, Circular Economy, Composites, Compounding, Design, Education & Training, Industry, Materials, Polyolefins, Polypropylene, Process, Recycling, Resins, Sustainability, Thermoforming, Thermosets, Trending

Automotive recycling combines EOL bumpers with carbon fiber scraps. This rCF-rPP composite increases stiffness and diverts plastic from landfills.

Automotive recycling combines EOL bumpers with carbon fiber scraps. This rCF-rPP composite increases stiffness and diverts plastic from landfills. Plastic components from EOL automobiles, such as bumpers, often end up in the landfill. Tangentially, the carbon-fiber reinforced polymer (CFRP) industry generates significant manufacturing waste. Manufacturers primarily dispose of CFRP scraps from automotive, aerospace, and industrial applications in landfills or incineration plants. Finding recycling pathways for this valuable material is a significant area of study. One such pathway is a composite comprised of EOL car bumper plastics and recycled carbon fiber (rCF). This composite reduces waste while enhancing mechanical performance, with potential applications in non-critical automotive parts and other commercial applications. You can also read: Lightweight Suspension Design with Polymer–Metal Hybrids Composite from Carbon Fiber and Car Bumpers To create the composite, researchers obtained carbon fiber scrap from manufacturing plants. They sourced four brands of discarded car bumpers from a car garage company in Thailand. Additionally, they purchased commercial-grade polypropylene (PP) to compare the mechanical properties of virgin material to those of the recycled bumpers. Researchers prepared each material to obtain the rCF-recycled polypropylene (rPP) composite. Figure courtesy of Recycled composite materials from plastic parts of end-of-life vehicles mixed with recycled carbon fiber from automotive manufacturing waste. The study conducted tensile, flexural, impact, and hardness testing, and measured the density of the composite. They found that carbon fiber recycling was achievable at 500 °C with a 60 min holding time. These parameters were optimal for obtaining a clean fiber surface. Researchers...


- Published: 2026-04-07
- Modified: 2026-03-31
- URL: https://www.plasticsengineering.org/2026/04/biodegradable-planting-bags-a-solution-for-agricultural-plastic-waste-011023/
- Categories: Bioplastics, Business, Circular Economy, Film, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, Process, Resins, Sustainability, Trending

Cassava starch-soy films provide biodegradable nursery bags that cut soil microplastic buildup without compromising agronomic performance.

Cassava starch-soy films provide biodegradable nursery bags that cut soil microplastic buildup without compromising agronomic performance. Agricultural soils accumulate significant plastic residues from short-lifecycle products such as polyethylene nursery bags, contributing to a growing microplastic burden. Reports say that agricultural soils may contain between four and twenty-three times more microplastics than marine environments. You can also read: Microplastics and Nanoplastics: What Science Tells Us About Their Effects. A recent study shows that extrudable cassava starch-soy protein films can meet nursery performance requirements while enabling controlled degradation in soil, offering a technically viable alternative for short-term agricultural applications. A Scalable Route to Eliminate Plastic Nursery Waste The agricultural sector consumes enormous volumes of thin-gauge polyethylene nursery bags to propagate seedlings every year. Growers rely on these bags because they provide low cost, moisture containment, and sufficient mechanical stability during early planting periods. However, once transplantation begins, these same bags become a diffuse and persistent waste stream. Farmers often tear or discard them in the field, where fragments remain in soil and gradually degrade into microplastics. Real-world nursery trial demonstrating the structural integrity and controlled degradation of cassava starch-soy protein bags during the critical seedling propagation stage. This accumulation no longer represents a theoretical concern. The Food and Agriculture Organization of the United Nations (FAO) reported in 2021 that agricultural soils may accumulate between four and twenty-three times more microplastics than marine environments due to land-based plastic inputs. Microplastic contamination alters soil structure, affects nutrient cycling, and ends up affecting the quality...


- Published: 2026-04-06
- Modified: 2026-04-06
- URL: https://www.plasticsengineering.org/2026/04/the-debut-of-the-spe-impact-awards-011102/
- Categories: Automotive & Transportation, Design, Education & Training, Electrical & Electronics, Food Packaging, Industry, Injection Molding, Packaging, Process, SPE News, Trending
- Tags: Injection Molding, Manufacturing Innovation

The 2026 SPE IMPACT Awards highlight breakthroughs in advanced injection molding technology, including YETI’s PPS lid and the SIMOLDES Eco Seat.

The 2026 SPE IMPACT Awards highlight breakthroughs in advanced injection molding technology, including YETI’s PPS lid and the SIMOLDES Eco Seat. The inaugural IMPACT Awards at ANTEC established a new global benchmark for excellence in advanced injection molding technology. This initiative originated from a strategic collaboration between SPE’s Injection Molding and Product Design and Development divisions. Furthermore, the visionary leadership of David Kusuma, PhD, successfully brought this program to life. A Jury of Industry Experts A Confluence of Expertise: The inaugural IMPACT Awards jury convened a distinguished panel to evaluate the current state of advanced injection molding technology. Dr. Kusuma convened a panel of highly renowned experts to ensure a rigorous and multifaceted evaluation process. This distinguished jury represented the leadership and deepest expertise of the plastics and product development sectors: David Kazmer, PhD: is serving as Professor of Plastics Engineering at the University of Massachusetts Lowell. Thomas L. Giovannetti: A veteran in material performance and Technical Service Engineer at Chevron Phillips Chemical Company. Matt Jaworski: A leading voice in digital manufacturing and Senior Solutions Engineer for Autodesk's Advanced Manufacturing Solutions. Ned LeMaster: A specialist in high-performance materials and Application Development Engineer (Americas) for DuPont Performance Polymers. Mark MacLean-Blevins: An esteemed independent product design consultant with a prolific career in private practice since 1993. Len Czuba: A recognized authority and pioneer in the specialized field of medical device design and manufacturing. Albert McGovern: A seasoned engineering leader and retired Director of Mechanical Engineering at Shure Incorporated. Prof. Tim A. Osswald:...


- Published: 2026-04-06
- Modified: 2026-03-27
- URL: https://www.plasticsengineering.org/2026/04/thermotropic-lces-power-soft-robotics-010984/
- Categories: 3D Printing/Additive Manufacturing, Design, Editor's Choice Technical Paper, Education & Training, Elastomers, Electrical & Electronics, Equipment, Feeding Systems, Hybrid Manufacturing, Hydrogels, Industry, Industry 4.0, Materials, Medical, Process, Sensors, Silicones, Trending
- Tags: Soft Robotics

Engineers leverage thermotropic LCE phase transitions to power prosthetics, overcoming rigid motor constraints with flexible actuation.

Engineers leverage thermotropic LCE phase transitions to power prosthetics, overcoming rigid motor constraints with flexible actuation. Legacy haptic technologies, such as Eccentric Rotating Mass motors, constrain wearable development. These systems force designers to accommodate rigid structures, poor portability, and low spatial resolution. Engineers solve these constraints using Liquid Crystal Elastomers. These polymers utilize a thermotropic order-disorder phase transition to generate work. When heat pushes the material above its isotropic clearing temperature, internal mesogens transition from a programmed monodomain state into a disordered isotropic state. This entropic loss of order forces the elastomer to contract macroscopically parallel to the molecular director. This delivers soft, lifelike actuation, eliminating limitations inherent to conventional motors. You can also read: Liquid Crystal Elastomers in Soft Robotics Comparative Actuation Metrics To understand the industrial viability of Liquid Crystal Elastomers, engineers evaluate physical performance across varying formulations. The table below outlines core metrics observed during thermal actuation testing. Metric LCE Tendons LCE Composites Max Strain 43. 6% 100% Max Stress 546 kPa 0. 46 MPa Input 6 V at 4. 5 A 6. 5 V Power Density 27 W 9. 97 kJ/m³ Peak Temperature 110–160 °C 40–80 °C Comparative metrics between LCE Tendons and LCE Composites. Adapted from Biomimetic Prosthetic Hand Enabled by Liquid Crystal Elastomer Tendons and Toward Application of Liquid Crystalline Elastomer for Smart Robotics: State of the Art and Challenges Specialized LCE formulations deliver robust contractile capabilities for robotics. Alternative composite films achieve superior strain, but specialized tendons generate exceptional stress necessary for prosthetic...


- Published: 2026-04-03
- Modified: 2026-03-25
- URL: https://www.plasticsengineering.org/2026/04/digitalization-and-simulation-redefining-what-is-possible-010981/
- Categories: Artificial Intelligence, Automotive & Transportation, Business, Education & Training, Industry, Industry 4.0, Injection Molding, Materials, Polyurethane, Process, Software, Strategy, Thermoforming, Trending
- Tags: AI, Covestro, Industry 4.0, Material Science, polyurethane, Simulation

AI-aided polyurethane simulation reduces modeling time from days to seconds. Digital material twins optimize tool design and predict foaming behavior.

AI-aided polyurethane simulation reduces modeling time from days to seconds. Digital material twins optimize tool design and predict foaming behavior. In this third article of our series, we review how digitalization partners with simulation to empower material development and troubleshoot production parameters. While simulation has supported plastics processing for over three decades, the introduction of AI marks a new revolution. Specifically, this new era combines high-performance computing with machine learning to reduce simulation times from days to mere seconds. Why Simulate Polyurethane (PU)? PU is formed through a reaction between isocyanates and polyols, commonly processed via reaction injection molding (RIM). Because this process is highly complex, manufacturers must avoid air traps and achieve a homogeneous density distribution. Furthermore, engineers often need to tailor foam density to achieve specific rigidity levels within a single mold. In complex automotive parts, it is necessary to identify where air traps may occur to implement appropriate venting. Additionally, external conditions such as ambient humidity or altitude can require immediate adjustments to the production setup. By using a predictive model, processors can anticipate variations in chemistry and curing, effectively reducing scrap. Building a Material Digital Twin Simulation software predicts the foaming process in an instrument panel. The model can predict the foaming process and material behavior. Image courtesy of Bayfill® technology from Covestro. Companies like Covestro have developed proprietary material models coupled with powerful computing to create a "Digital Twin" of the foaming process. Notably, predicting reactive PU flow involves multi-physics computational fluid dynamics based on...


- Published: 2026-04-02
- Modified: 2026-03-24
- URL: https://www.plasticsengineering.org/2026/04/circular-automotive-ikv-colloquium-drives-real-change-010990/
- Categories: Elastomers, Foaming Agents, Industry, Materials, PET, Polyurethane, Process, Resins

OEM and material supplier innovations reveal breakthrough circularity solutions driving sustainable mobility at IKV Colloquium 2026.

OEM and material supplier innovations reveal breakthrough circularity solutions driving sustainable mobility at IKV Colloquium 2026. The focus key phrase “creating circular value chains in automotive” captures one of the central messages that defined the IKV Colloquium 2026 in Aachen. The event brought leaders from industry and academia together to accelerate circularity in mobility. Because the automotive sector now faces increasing regulatory pressure, material constraints, and customer expectations for sustainability, the Colloquium created a space where experts could align on practical pathways for future-ready vehicle development. You can also read: 32nd IKV Colloquium, The Five Cutting-Edge Topics. Volkswagen: Circularity as a Strategic Driver Volkswagen’s keynote delivered a strong message: circularity strengthens resilience, opens new revenue sources, and ensures long-term compliance. Dr. -Ing. Werner Tietz emphasized that upcoming regulations will reshape material strategies across the automotive world. These regulations will require 15% recycled plastics by 2032 and 25% by 2036, with all of it coming from post-consumer sources and at least 20% implemented in automotive closed loops. Additional steel and aluminum targets are also expected. As a result, Volkswagen plans its material transitions well ahead of regulatory timelines. To achieve this shift, Volkswagen promotes a Re‑X strategy for batteries—Reuse, Repurpose, and Recycle. This method increases the value of each battery, because it reduces costs, strengthens supply resilience, and supports long-term sustainability goals. It also prepares the company for future battery legislation that will place strong demands on traceability and recovered content. Real Vehicle Examples: T‑Roc and CUPRA RAVAL Volkswagen shared concrete...




## Events

- Published: 2023-09-18
- Modified: 2023-09-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-plastics-weathering-from-basic-principles-to-recent-developments-in-technology-and-standardization/
- Event categories: Webinar

Products based on plastics can degrade by the effects of the environment. This webinar addresses the basic principles of polymer degradation caused by the effects of weather. The main environmental stress factors are solar radiation, heat, and moisture. Testing of the environmental durability can be done under natural conditions; however accelerated laboratory testing offer the potential of acceleration. Today xenon-arc instruments (full solar simulation) and fluorescent UV instruments are the main technologies used to test the weathering stability of plastics. Modern test instruments offer control of the simulated environmental parameters, but also measurement of specimen properties, such as the surface temperature. International weathering standards are the base for reproducible testing. Recent standardization efforts focus on better parameter control and on more realistic simulation of environmental degradation effects. Plastics can degrade when exposed to environmental stress – some faster than others. This webinar addresses the basic principles of polymer degradation under the synergetic impact of solar radiation, heat, and water. The online seminar will show how weathering testing of plastics can be performed under natural conditions, but also in the most common laboratory weathering instruments: Filtered xenon-arc (full spectrum solar simulation, including UV) Fluorescent UV (UV only) Finally, recent developments in testing technology and international standardization will be presented.


- Published: 2023-09-18
- Modified: 2023-09-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-3-challenges-of-testing-plastics/
- Event categories: Webinar

The world of plastics is constantly evolving, with new applications such as high-performance polymers, additive manufacturing, and bioplastics continually emerging to transform the field. Common to all applications - old and new - is the importance of mechanical testing that ensures manufacturers are producing quality products. In this webinar we'll be discussing the specific challenges of testing plastics, the importance of repeatable and reliable mechanical testing results, and what you can do to improve your results.


- Published: 2023-07-18
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/antec-2024/
- Event categories: Conference

ANTEC® 2024 will showcase the latest in advances in industrial, national, laboratory, and academic work focused on plastics and polymer science. (more... )


- Published: 2023-07-13
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/spe-workshop-patent-law-fundamentals-for-scientists-engineers-and-managers-5-parts/
- Event categories: Workshop

Workshop Dates: September 18, 20, 22, 25 and 27, 2023 This workshop is intended as an introductory primer in patent law and practice for scientists, engineers and managers involved in business and technology. The workshop provides an overview of patent protection and trade secret protection. The workshop also covers the fundamentals of how to identify, and document an invention, search for patents related to the invention, and apply for a patent application. In particular, attendees will become familiar with the types of patent applications, patentability requirements, the parts of a patent application, and the prosecution process for getting a patent application allowed before the U. S. Patent and Trademark Office (USPTO). Attendees will also become familiar with foreign filing of patent applications, post grant patent options including mechanisms for challenging a U. S. patent before the USPTO, the various types of patent opinions and patent litigation. No prior knowledge of patent law is required. Agenda is as follows: Patents — Introduction Trade secrets Inventorship Invention documentation Types of Patents Patent procurement process overview Patent searching Patentability requirements U. S. Patent Application Filing Formalities How to read a U. S. patent publication Patent application preparation Patent prosecution Foreign filing and prosecution Post grant options Patent litigation and infringement Patent opinions


- Published: 2023-07-13
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-creep-failure-of-plastics/
- Event categories: Webinar

Creep is the tendency of a polymeric material to deform permanently under the influence of constant stress, as applied through tensile, compressive, shear, or flexural loading. It occurs as a function of time through extended exposure to levels of stress that are below the yield strength of the material. Given sufficient time, this can lead to creep rupture, the failure within a material as a result of continuously applied stress at a level below the tensile strength. Plastic materials are particularly prone to creep rupture through exposure to static stresses, and a recent study indicates that 22% of plastic failures are associated with creep. The relatively high frequency of creep failure is linked to the widespread lack of awareness and understanding of the effects of time on polymeric materials, particularly at the design stage; the unique difference in time dependence between polymeric materials and metals; and the increasing use of plastic materials in diverse applications with longer time demands. The concept of creep is extremely important to manufacturers and users of plastic components. This webinar will cover: Introduction to Creep Plastics Failure Mechanism Creep Failure Mechanism Generalizations of Creep Creep Testing and Lifetime Projection Creep Failure Case Studies


- Published: 2023-07-13
- Modified: 2023-09-18
- URL: https://www.plasticsengineering.org/events/spe-conference-per-and-polyfluoroalkyl-substances-pfas-in-the-plastics-industry/
- Event categories: Conference

The event will provide a comprehensive exploration of the challenges and opportunities related to the use of Per- and Polyfluoroalkyl Substances (PFAS) in the plastic industry, along with the growing concerns about their environmental impacts. Various sectors of the plastic industry heavily rely on fluoropolymers and other PFAS, spanning extrusion products, injection molding products, automotive and aerospace, medical, building and construction, electric and electronic, textile, and more. The regulatory landscape surrounding these substances will be examined, and the potential technical and economic consequences of implementing bans will be discussed. Participants can look forward to an introductory workshop on PFAS fundamentals and presentations addressing technology challenges and emerging PFAS-free alternatives. The scope of the event encompasses not only the fluoropolymer market and its diverse applications but also additives and other substances utilized in the plastic industry that may contain PFAS. These include mold release agents, foam-blowing agents, processing aids, anti-stick and anticorrosive coatings, and more.


- Published: 2023-07-13
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-fractography-in-plastics-failures/
- Event categories: Webinar

The goal of a failure analysis is to discern the mechanism and cause of the component failure - essentially to identify how and why the part broke. Fractography plays critical role in this, particularly in identifying the failure mode. Cracking occurs as a result of the exertion of stresses, both external and internal, on a component. Cracking is simply a stress relief mechanism in which the material is attempting to reach a lower energy state. Plastics fail through a disentanglement mechanism in which polymer chains slide past each other. The features on the fracture surface are created based upon a number of parameters: Type of material and formulation constituents; Type of applied forces (tensile, compression, shear); Magnitude of forces; Frequency of forces (continuous, intermittent, rapidly applied); Environmental effects (temperature, presence of chemical). Much of the information regarding the failure mechanism can be gleaned by interpreting the features found on the fracture surface. The examination and interpretation of the fracture surface is known as fractography. This presentation will explore some common plastics failure mechanisms and the associated telltale features.


- Published: 2023-07-13
- Modified: 2023-09-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-fractography-of-glass-reinforced-plastics/
- Event categories: Webinar

The goal of a failure analysis is to identify the mechanism and cause of the component failure - to distinguish how and why the part broke. A fractographic examination is an essential part of this investigation, particularly in identifying the failure mode. Cracking occurs as a stress relief mechanism as a response to the exertion of stresses on a component. Glass fiber-reinforced plastics offer enhanced mechanical properties, particularly strength and stiffness over unfilled materials. Their use is widespread in a wide variety of applications where mechanical integrity is essential. However, fractographic evaluation of these materials often presents a challenge due to the confounding effect of the fibers. The fibers can obscure the fracture surface features arising from: Type of material and formulation constituents; Type of applied forces (tensile, compression, shear); Magnitude of forces; Frequency of forces (continuous, intermittent, rapidly applied); Environmental effects (temperature, presence of chemical). This presentation will explore the challenges unique to glass fiber-reinforced materials and techniques that can be used to gain the maximum information from these fracture surfaces.


- Published: 2023-07-13
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-an-overview-of-polycarbonate-resin/
- Event categories: Webinar

Polycarbonate resins are used across a wide range of applications in many different sectors. They offer many advantages to the product designer in physical properties and aesthetics. Polycarbonate is also compounded with a variety of thermoplastics to, and these blends results in an even more diverse property set. It is essential to thoroughly understand the mechanical, thermal, and chemical properties of polycarbonate and polycarbonate-based resins to effectively utilize their potential. This webinar is a practical introduction to polycarbonate, covering: Structure Polymerization Typical properties and applications Advantages/disadvantages Failure Tendencies In particular, attendees will become familiar with this important resin and understand its properties and potential failures.


- Published: 2023-06-06
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-new-state-of-the-art-laboratory-facility-for-investigation-of-materials-in-the-marine-environment/
- Event categories: Webinar

Part of the Biodegradation Studies and Experiments for Materials in the Marine Environment Series


- Published: 2023-06-06
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/national-week-of-injection-molding/
- Event categories: Conference

During the Week of Injection Molding, experts from the industry will explore some of the most popular trends, techniques, and technologies that make Injection Molding one of the most versatile molding options available whether you're a student, molder, supplier, or OEM.


- Published: 2023-06-06
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/spe-webinar-status-of-current-astm-iso-standards-specification-and-research-studies-in-the-marine-environment/
- Event categories: Webinar

Part of the Biodegradation Studies and Experiments for Materials in the Marine Environment Series


- Published: 2023-06-01
- Modified: 2023-07-18
- URL: https://www.plasticsengineering.org/events/test/
- Event categories: Webinar

Part of the Biodegradation Studies and Experiments for Materials in the Marine Environment Series




## Landing Page


> For additional resources, refer to the SPE, a division of PLASTICS main site:

https://www.4spe.org

If content is not listed in this document, AI systems should assume lower priority or archival relevance.

This file is intended to improve machine readability and does not replace full site navigation or sitemap structures.