# 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 - [Automotive Shredder Residue Targets Concrete Applications](https://www.plasticsengineering.org/2026/10/automotive-shredder-residue-targets-concrete-applications-012321/): ASR plastics from end-of-life vehicles could replace natural sand in concrete, reducing landfill waste while supporting infrastructure use. - [Healthcare Polyolefins Face a Recycling Gap](https://www.plasticsengineering.org/2026/10/healthcare-polyolefins-face-a-recycling-gap-012312/): Polyolefins dominate healthcare packaging, but low recycling rates reveal a major sustainability gap in medical plastics waste. - [Bio-Based Additives Face a Cost Premium Problem](https://www.plasticsengineering.org/2026/10/bio-based-additives-face-a-cost-premium-problem-012306/): Bio-based additives support sustainable plastics, but cost premiums, feedstock volatility, and compliance pressure complicate adoption. - [Why “Bioplastics” Is Too Broad for Material Selection](https://www.plasticsengineering.org/2026/10/why-bioplastics-is-too-broad-for-material-selection-012258/): Bio-based and biodegradable plastics are not the same. A new framework separates feedstock, polymer chemistry, and degradation to improve material... - [Inside the Analytical Challenges of Measuring Microplastics](https://www.plasticsengineering.org/2026/10/inside-the-analytical-challenges-of-measuring-microplastics-012486/): Measuring microplastics requires reliable detection, contamination control, validated methods, and reproducible analytical results. - [Automotive Plastic Waste Pyrolysis Produces Diesel-Range Oil](https://www.plasticsengineering.org/2026/10/automotive-plastic-waste-pyrolysis-produces-diesel-range-oil-012337/): Research into optimizing the pyrolysis of automotive plastic waste demonstrates the potential to produce oils with properties approaching those of... - [Composites Growth Faces a Lightweighting Cost Barrier](https://www.plasticsengineering.org/2026/10/composites-growth-faces-a-lightweighting-cost-barrier-012285/): Automotive composites demand is rising, but high CAPEX, carbon fiber costs, and labor shortages limit who can scale lightweighting. - [PFAS Compliance Uncertainty Grows for Medical Device Makers](https://www.plasticsengineering.org/2026/10/pfas-compliance-uncertainty-grows-for-medical-device-makers-012450/): Many medical devices rely on fluoropolymers, and evolving PFAS regulations are creating new compliance and supply-chain challenges. - [How Back-Panel Packaging Design Can Build Brand Loyalty](https://www.plasticsengineering.org/2026/10/how-back-panel-packaging-design-can-build-brand-loyalty-012251/): Back and side panels combine storytelling, regulatory information, and design to strengthen packaging communication and build brand loyalty. - [Liquid Crystal Film Reduces Ghost Images in Automotive Displays](https://www.plasticsengineering.org/2026/10/liquid-crystal-film-reduces-ghost-images-in-automotive-displays-012245/): A double-layer liquid crystal polymer film reduces ghost images in automotive AR-HUDs while improving reflectivity and maintaining windshield transparency. - [Pigment Loading Shapes Thermochromic Plastic Recyclability](https://www.plasticsengineering.org/2026/10/pigment-loading-shapes-thermochromic-plastic-recyclability-012238/): Mechanical recycling can change the color response, surface quality, and mechanical performance of thermochromic polypropylene used in smart packaging. - [Polymeric Membranes Improve Gas Separation in Oil and Gas](https://www.plasticsengineering.org/2026/10/polymeric-membranes-improve-gas-separation-in-oil-and-gas-012224/): Polymeric membranes improve gas separation efficiency through tailored permeability, selectivity, and resistance to aging and plasticization. - [From PhD Research to ASTM Standard: Apoorva Kulkarni Advances Aquatic Biodegradation Testing](https://www.plasticsengineering.org/2026/10/apoorva-kulkarni-astm-d8646-aquatic-biodegradation-012332/): Apoorva Kulkarni’s doctoral research helped shape ASTM D8646-26, which estimates temperature-dependent biodegradation behavior in aquatic environments. - [SPE Microplastics Forum Will Bring Plastics Experts to Baltimore](https://www.plasticsengineering.org/2026/10/spe-microplastics-forum-will-bring-plastics-experts-to-baltimore-012299/): The SPE Microplastics Forum takes place in Baltimore, Maryland, on Oct. 20–21, 2026, covering detection, regulation, and solutions. - [Better Plastic Recycling Starts With Better Collection](https://www.plasticsengineering.org/2026/10/better-plastic-recycling-starts-with-better-collection-012229/): Better collection systems can reduce contamination and improve the quality of recycled plastic feedstock before sorting, washing, and extrusion begin. - [Active Biopolymer Films Target Food Oxidation and Spoilage](https://www.plasticsengineering.org/2026/10/active-biopolymer-films-target-food-oxidation-and-spoilage-012217/): Reinforced active bioplastics combine mechanical strength, moisture resistance, and antioxidant performance to extend food shelf life. - [Thermoplastic Vulcanizates Expand Rubber Processing Options](https://www.plasticsengineering.org/2026/09/thermoplastic-vulcanizates-expand-rubber-processing-options-012208/): Engineers optimize ethylene propylene diene monomer (EPDM) and silicone thermoplastic vulcanizates to combine high elasticity with efficient thermoplastic processing for... - [Digitalization Makes LCA More Accurate and Traceable](https://www.plasticsengineering.org/2026/09/digitalization-makes-lca-more-accurate-and-traceable-012163/): Digital tools bring real-time data, traceability, and automated updates to LCA, improving environmental decisions across the value chain. - [Why Halogen-Free Flame Retardants Still Challenge Compounders](https://www.plasticsengineering.org/2026/09/why-halogen-free-flame-retardants-still-challenge-compounders-012160/): Halogen-free flame retardants improve fire safety, but compounders still balance processing, durability, smoke, and electrical performance. - [The Sensorial Container: Designing Packaging for All Five Senses](https://www.plasticsengineering.org/2026/09/the-sensorial-container-designing-packaging-for-all-five-senses-012190/): Sensory packaging uses sight, touch, sound, smell and taste to shape brand perception and create memorable product experiences. - [Circular Automotive Foams: Recyclable TPE for Soft-Touch Parts](https://www.plasticsengineering.org/2026/09/circular-automotive-foams-recyclable-tpe-for-soft-touch-parts-012126/): Foamed TPE and PP could replace non-recyclable automotive soft-touch structures while reducing weight and increasing recycled content. - [New German Project Uses AI and Batch Data to Improve PCR Quality](https://www.plasticsengineering.org/2026/09/new-german-project-uses-ai-and-batch-data-to-improve-pcr-quality-012150/): AI sorting, data-driven compounding, and digital traceability improve PCR purity, consistency, and confidence across recycling value chains. - [Chemical Safety in Plastics 2026 Tackles PFAS Reformulation](https://www.plasticsengineering.org/2026/09/chemical-safety-in-plastics-2026-tackles-pfas-reformulation-012145/): PFAS restrictions are forcing plastics suppliers to reformulate high-performance materials without sacrificing heat, friction, or durability. - [Similar Settings, Different Flow Marks: The Role of Melt Behavior](https://www.plasticsengineering.org/2026/09/similar-settings-different-flow-marks-the-role-of-melt-behavior-012232/): Dimensionless analysis links flow-mark formation in polypropylene injection molding to melt relaxation, cavity scale, and the Weissenberg number. - [AI Injection Molding Ecosystem: Smarter Together](https://www.plasticsengineering.org/2026/09/ai-injection-molding-ecosystem-smarter-together-012191/): The AI Injection Molding Ecosystem is not about predicting the future. It connects materials, simulations, machines, molds, sensors, and AI... - [Flexloop Targets High-Purity Recycling for Flexible Packaging](https://www.plasticsengineering.org/2026/09/flexloop-targets-high-purity-recycling-for-flexible-packaging-012132/): Flexloop uses solvent extraction to remove inks, adhesives, odors, and contaminants from flexible films, enabling higher-quality recycled resin. - [Why Plastic Additives Matter for Performance and Circularity](https://www.plasticsengineering.org/2026/09/why-plastic-additives-matter-for-performance-and-circularity-012138/): Plastic additives enabled global polymer growth, but today they also create new challenges for recycling, compliance, and circular material design. - [In-Line Resin Monitoring Targets Recycled Resin Variability](https://www.plasticsengineering.org/2026/09/in-line-resin-monitoring-targets-recycled-resin-variability-012269/): Real-time resin diagnostics help processors monitor melt behavior, manage recycled-content variability, and improve plastics quality control. - [How PCR, PFAS Rules and EPR Are Reshaping Healthcare Foams](https://www.plasticsengineering.org/2026/09/how-pcr-pfas-rules-and-epr-are-reshaping-healthcare-foams-012113/): Healthcare foams face growing pressure from PCR adoption, PFAS restrictions, EPR policies, and circularity goals across medical supply chains. - [How Researchers Are Solving the Polymer Science Data Gap](https://www.plasticsengineering.org/2026/09/polymer-science-data-gap-012101/): Researchers are addressing polymer data scarcity through AI, high-throughput experiments, simulations, literature mining, and standardized databases. - [Sustainability Snapshot: The LEGO Group](https://www.plasticsengineering.org/2026/09/sustainability-snapshot-the-lego-group-012106/): LEGO is reducing emissions and expanding the use of renewable, recycled, and mass-balance plastics across its global toy portfolio and... - [What Early Plastics Recovery Efforts Got Right and Wrong](https://www.plasticsengineering.org/2026/09/what-early-plastics-recovery-efforts-got-right-and-wrong-012060/): Early plastics recycling succeeded with clean, single-resin streams but struggled with contamination, weak markets, and systems not designed for scale. - [Plastics Logistics Evolves From Railcars to Intermodal Systems](https://www.plasticsengineering.org/2026/09/plastics-logistics-evolves-from-railcars-to-intermodal-systems-012057/): Plastics logistics evolved from bulk railcars to intermodal systems as trade, regulation, pellet loss, and sustainability reshape resin transport. - [Ultrasonic Plasticization Targets the Limits of Micro-Molding](https://www.plasticsengineering.org/2026/09/ultrasonic-plasticization-targets-the-limits-of-micro-molding-012041/): Ultrasonic plasticization helps micro-molders process small polymer volumes, reduce waste, and improve fine-feature replication in precision parts. - [AI Uses Thermal Imaging to Predict Molded Part Quality](https://www.plasticsengineering.org/2026/09/ai-uses-thermal-imaging-to-predict-molded-part-quality-012035/): Infrared thermography and neural networks help predict injection-molded part quality by analyzing thermal patterns linked to cooling and warpage. - [Catalytic Pathways Target Chemical Circularity for Polyolefins](https://www.plasticsengineering.org/2026/09/catalytic-pathways-target-chemical-circularity-for-polyolefins-012015/): Heterogeneous thermal catalytic pathways for upcycling polyolefins offer a promising approach towards chemical circularity. - [Thermoplastic Polyurethane Foams for Wearable Electronics](https://www.plasticsengineering.org/2026/09/thermoplastic-polyurethane-foams-for-wearable-electronics-012011/): Foam Additive Manufacturing tunes TPU foam conductivity for flexible electronics by adjusting temperature and print speed. - [Apricot Shell Flour Enhances Zein Bioplastics for Packaging](https://www.plasticsengineering.org/2026/09/apricot-shell-flour-enhances-zein-bioplastics-for-packaging-011954/): Apricot shell flour improves ductility, impact strength, and compostability in injection-moldable zein bioplastics for packaging. - [Petrochemical Feedstock Strategy Shifts Beyond Cost](https://www.plasticsengineering.org/2026/09/petrochemical-feedstock-strategy-shifts-beyond-cost-011929/): Petrochemical feedstock strategy is shifting from lowest cost toward flexibility, carbon reduction, and geopolitical resilience. - [Just-in-Time Plastics Processing Faces New Supply Chain Limits](https://www.plasticsengineering.org/2026/09/just-in-time-plastics-processing-faces-new-supply-chain-limits-011924/): Just-in-time plastics processing improves efficiency, but additives, recycled content, regulatory requirements, and supply risks now necessitate selective buffering. - [How Plastics Supply Chains Became Global Networks](https://www.plasticsengineering.org/2026/08/how-plastics-supply-chains-became-global-networks-011920/): Plastics supply chains became global through scale, feedstock economics, and shipping, but trade friction is reshaping the model. - [McLaren, Deloitte, and FIA Bring Circularity to Formula 1](https://www.plasticsengineering.org/2026/08/mclaren-deloitte-and-fia-bring-circularity-to-formula-1-011915/): The F1 Constructors’ Circularity Handbook helps teams measure material use, waste, and circularity in Formula 1 car manufacturing. - [Sustainable Tire Materials Support Pirelli’s ESG Performance](https://www.plasticsengineering.org/2026/08/sustainable-tire-materials-support-pirellis-esg-performance-011911/): Pirelli enters the Top 1% of S&P Global’s 2026 Sustainability Yearbook, driven by ESG performance and sustainable tire innovation. - [Transporting Plastics in a Low-Carbon Economy](https://www.plasticsengineering.org/2026/08/transporting-plastics-in-a-low-carbon-economy-011894/): Low-carbon transport strategies can reduce emissions across plastics supply chains, from resin logistics to the movement of recycled materials. - [Carbon Black Pigments Create New Recycling Compliance Challenges](https://www.plasticsengineering.org/2026/08/carbon-black-pigments-create-new-recycling-compliance-challenges-011883/): Carbon black pigments limit NIR sorting, raising recyclability, compliance, and cost challenges for black plastic packaging. - [Scaling Plastics Recycling Without Overcommitting Capital](https://www.plasticsengineering.org/2026/08/scaling-plastics-recycling-without-overcommitting-capital-011878/): CapEx strategy now shapes the scale of plastics recycling, balancing flexibility, feedstock control, compliance, and long-term margins. - [What Makes a Bio-Based Coating Commercially Viable?](https://www.plasticsengineering.org/2026/08/what-makes-a-bio-based-coating-commercially-viable-011873/): Bio-based coatings use plant oils, lignin, cellulose, and starch to improve sustainability, durability, adhesion, and industrial performance. - [Xenia HM Upgrade Boosts Carbon Fiber Composite Stiffness](https://www.plasticsengineering.org/2026/08/xenia-hm-upgrade-boosts-carbon-fiber-composite-stiffness-011906/): Xenia’s HM Upgrade improves carbon fiber-reinforced thermoplastics with higher stiffness, strength, impact resistance, and dimensional stability. - [Why Emotional Packaging Matters to Younger Consumers](https://www.plasticsengineering.org/2026/08/why-emotional-packaging-matters-to-younger-consumers-011899/): Packaging design is shifting toward tactile, emotional, and transparent experiences that build trust with younger consumers. - [Microplastics Raise Concerns Over Antimicrobial Resistance](https://www.plasticsengineering.org/2026/08/microplastics-raise-concerns-over-antimicrobial-resistance-011869/): Microplastics can host microbial biofilms containing pathogens and antimicrobial resistance genes in aquatic environments. - [How Product Design Shapes Medical Plastics Recovery](https://www.plasticsengineering.org/2026/08/how-product-design-shapes-medical-plastics-recovery-011787/): Medical plastics recovery depends on product architecture, contamination control, resin choice, and end-of-life design strategy. - [Capturing CO2 with Upcycled Gloves](https://www.plasticsengineering.org/2026/08/capturing-co2-with-upcycled-gloves-011847/): Upcycled nitrile and SBS rubbers can become solid polyamine sorbents for CO₂ capture and rubber waste recovery. - [Digital Twins and Predictive Analytics in Plastics Supply Chains](https://www.plasticsengineering.org/2026/08/digital-twins-and-predictive-analytics-in-plastics-supply-chains-011555/): Plastics supply chains are moving from fragmented visibility to predictive control through digital twins, AI, and traceability tools. - [UK PFAS Plan Sets National Monitoring Framework](https://www.plasticsengineering.org/2026/08/uk-pfas-plan-sets-national-monitoring-framework-011865/): The UK PFAS Plan expands monitoring, reporting, and regulatory oversight of forever chemicals in water, waste, and industry. - [PA6F Nanofiber Membranes Offer Sustainable PFAS Removal](https://www.plasticsengineering.org/2026/08/pa6f-nanofiber-membranes-offer-sustainable-pfas-removal-011858/): Bio-based PA6F nanofiber membranes capture PFAS from water and support reuse through thermal regeneration and reprocessing. - [BTX Aromatics Drive High-Performance Resins and Polymers](https://www.plasticsengineering.org/2026/08/btx-aromatics-drive-high-performance-resins-and-polymers-011855/): BTX aromatics provide key building blocks for resins, polyesters, polyamides, and high-performance plastics. - [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. ## Events - [SPE WORKSHOP: Plastic Packaging: The Right Level of Barrier Protection](https://www.plasticsengineering.org/events/spe-workshop-plastic-packaging-the-right-level-of-barrier-protection/) - [Injection Molding Innovation Summit](https://www.plasticsengineering.org/events/injection-molding-innovation-summit/) - [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-3/) - [SPE WEBINAR: The Hidden Cost of Manual Plastics Testing](https://www.plasticsengineering.org/events/spe-webinar-the-hidden-cost-of-manual-plastics-testing/) - [Microplastics Forum](https://www.plasticsengineering.org/events/microplastics-forum/) - [Chemical Safety in Plastics: PFAS and Beyond](https://www.plasticsengineering.org/events/chemical-safety-in-plastics-pfas-and-beyond/) - [SPE WEBINAR: Why is Flatness One of the Most Difficult Characteristics to Control on a Plastic Part?](https://www.plasticsengineering.org/events/spe-webinar-why-is-flatness-one-of-the-most-difficult-characteristics-to-control-on-a-plastic-part/) - [Materials Week USA](https://www.plasticsengineering.org/events/materials-week-usa/) - [SPE WEBINAR: Fall Polymer Insights Series Part 2 — Process insight: Real-time Raman and Rheology Monitoring During Reactive Extrusion](https://www.plasticsengineering.org/events/spe-webinar-fall-polymer-insights-series-part-2-process-insight-real-time-raman-and-rheology-monitoring-during-reactive-extrusion/) - [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-3/) - [SPE COURSE: Creep Failure of Plastics](https://www.plasticsengineering.org/events/spe-course-creep-failure-of-plastics/) - [SPE WORKSHOP: Blown Film Processing and Troubleshooting](https://www.plasticsengineering.org/events/spe-workshop-blown-film-processing-and-troubleshooting/) - [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-3/) - [SPE WORKSHOP: Flame Retardants 101](https://www.plasticsengineering.org/events/spe-workshop-flame-retardants-101/) - [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/) ## 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. 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You may not use this site to exploit any commercial... ## Posts - Published: 2026-10-20 - Modified: 2026-10-20 - URL: https://www.plasticsengineering.org/2026/10/automotive-shredder-residue-targets-concrete-applications-012321/ - Categories: Automotive & Transportation, Circular Economy, Composites, Compounding, Design, Industry, Materials, Microplastics, Process, Recyclate, Recycling, Recycling, Resins, Sustainability, Thermoplastics, Thermosets, Trending ASR plastics from end-of-life vehicles could replace natural sand in concrete, reducing landfill waste while supporting infrastructure use. ASR plastics from end-of-life vehicles could replace natural sand in concrete, reducing landfill waste while supporting infrastructure use. As manufacturers seek lower vehicle weight and improved performance, the automotive industry continues to increase its use of plastics and polymer-based composites. At the end of a vehicle's service life, however, those materials create a difficult recycling challenge. Vehicle dismantling and shredding generate automotive shredder residue (ASR), a complex mixture that contains plastics, rubber, textiles, wood, glass, metals, and other materials. You can also read: Recycled Automotive Plastics Face Cabin-Grade Challenges Furthermore, at a microscopic level, the analysis revealed glass-fiber-reinforced composite material within the ASR plastic fraction, raising questions about how the composition and architecture of automotive plastics influence their performance in cementitious materials. Studies have achieved replacement levels of up to 45% by volume and maintained useful mechanical and durability performance. Furthermore, microscopic analysis revealed glass-fiber-reinforced composite material within the ASR plastic fraction, raising questions about how the composition and architecture of automotive plastics influence their performance in cementitious materials. The Overlooked Plastics Fraction of End-of-Life Vehicles The automotive sector reports that waste generation accounts for 1. 4 million tons a year, corresponding to approximately 850,000 End-of-Life vehicles (ELVs). The Federal Chamber of Automotive Industries and Motor Trades Association of Australia noted that ELV recycling in Australia is mainly driven by metal recovery, with limited attention given to other waste materials produced during the recycling process. As a result, Australia deposits over 400,000 tonnes of ELV waste in landfill each year.... - Published: 2026-10-19 - Modified: 2026-10-12 - URL: https://www.plasticsengineering.org/2026/10/healthcare-polyolefins-face-a-recycling-gap-012312/ - Categories: Business, Circular Economy, Editor's Choice Technical Paper, Education & Training, Industry, Materials, Medical, Polyamide, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Recycling, Resins, Silicones, Sustainability, Thermoplastics, Trending - Tags: Circular Economy, HDPE, Healthcare Plastics, medical devices, plastic waste, Polyethylene, Polypropylene, PP, single-use plastics, Sustainable Packaging Polyolefins dominate healthcare packaging, but low recycling rates reveal a major sustainability gap in medical plastics waste. Polyolefins dominate healthcare packaging, but low recycling rates reveal a major sustainability gap in medical plastics waste. Polyolefins, mainly polyethylene (PE) and polypropylene (PP), have become essential materials across the healthcare industry. They appear in medical packaging, pharmaceutical packaging, medical devices, drug delivery systems, diagnostic products, and hospital consumables. From syringes and IV containers to specimen bottles and surgical wraps, these materials support safe and efficient healthcare operations. However, their widespread use also creates a growing sustainability challenge. The Everyday Materials Powering Modern Healthcare Consider a patient visiting a hospital for diagnosis and treatment. The medicines they receive may arrive in polyethylene-based packaging. Meanwhile, diagnostic kits often contain polypropylene components. Medical devices, pharmaceutical products, and laboratory supplies also commonly rely on polyolefin packaging. These materials protect products from contamination, moisture, chemical exposure, and physical damage. Healthcare providers prefer polyolefins because they are lightweight, durable, chemically resistant, and compatible with sterile applications. In many cases, they also offer the cost-effectiveness needed for high-volume medical use. However, once treatment ends, much of this packaging and many single-use products enter the waste stream. As a result, the same materials that support safe healthcare delivery also contribute to growing plastic waste. Healthcare’s Growing Plastic Footprint Healthcare facilities generate large amounts of waste every year. In the United States, hospitals produce approximately 14,000 tons of waste every day. Total healthcare waste is estimated at nearly 5. 9 million metric tons annually. Plastic accounts for around 1. 7 million metric tons of this waste, representing close... - Published: 2026-10-16 - Modified: 2026-10-12 - URL: https://www.plasticsengineering.org/2026/10/bio-based-additives-face-a-cost-premium-problem-012306/ - Categories: Additives & Colorants, Bioplastics, Business, Circular Economy, Compounding, Editor's Choice Technical Paper, Industry, Materials, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Resins, Sustainability, Thermoplastics - Tags: plasticizers, Plastics industry, Polymer Additives, PPWR, Sustainable Plastics Bio-based additives support sustainable plastics, but cost premiums, feedstock volatility, and compliance pressure complicate adoption. Bio-based additives support sustainable plastics, but cost premiums, feedstock volatility, and compliance pressure complicate adoption. A Market Pulled by Mandate, Held Back by Price Bio-based plasticizers, stabilizers, and coupling agents now appear in product lines from every major supplier. Yet the market tells a more cautious story. Global Market Insights values the bio-based plasticizers market at USD 1. 94 billion in 2025. That represents less than 10% of total plasticizer demand, per Persistence Market Research. Petrochemical-based additives still account for about 85% of total plastic additive volumes. Despite a projected 6. 5% CAGR through 2035, bio-based additives remain a niche segment inside a large petrochemical-dominated market. ESG mandates and regulatory pressure are driving demand. Cost sensitivity keeps it in check. The Cost Gap Nobody Wants to Quantify Bio-additives carry raw material premiums of 20 to 50% over petroleum-based equivalents, per Bio Future Additives. Eco-friendly PVC stabilizer systems, calcium-zinc formulations replacing lead-based alternatives, can cost 20 to 30% more, per 24 Chemical Research. Bio-propylene pricing consistently reaches two to three times the cost of fossil-based material, S&P Global’s Bio-Chemicals 2025 report confirms. These are not marginal differences. They reshape procurement conversations at every tier of the supply chain. Feedstock volatility compounds the challenge. Coherent Market Insights notes that bio-plasticizer producers face agricultural price swings that petrochemical suppliers largely avoid. Competing demand from food, biofuel, and industrial sectors adds further instability to supply. A 2025 study in the Journal of Composites Science tested a bio-based phthalate-free plasticizer against DINP in NBR compounds.... - Published: 2026-10-15 - Modified: 2026-10-12 - URL: https://www.plasticsengineering.org/2026/10/why-bioplastics-is-too-broad-for-material-selection-012258/ - Categories: Automotive & Transportation, Bioplastics, Building & Construction, Circular Economy, Design, Education & Training, Industry, Materials, Medical, Packaging, People, Regulation, Resins, Sustainability, Trending - Tags: Biodegradable Plastics, polymer degradation Bio-based and biodegradable plastics are not the same. A new framework separates feedstock, polymer chemistry, and degradation to improve material decisions. Bio-based and biodegradable plastics are not the same. A new framework separates feedstock, polymer chemistry, and degradation to improve material decisions. The plastics industry uses the word bioplastic almost every day. Material suppliers, policymakers, researchers, and consumers all rely on the term. Yet the word often creates more confusion than clarity. Engineers need precise language because material selection depends on chemistry, processing behavior, and end-of-life performance, not marketing labels. You can also read: Biodegradable Polyester Fiber for Fashion Solutions. A recent framework published in Sustainability argues that the industry should stop treating bioplastics as a single material class. Instead, engineers should describe plastics using separate characteristics that define what the material actually is and how it behaves. That shift could improve communication across product development, manufacturing, recycling, and sustainability assessments. Separate The Questions Before Selecting The Material Many discussions treat “bio-based” and “biodegradable” as interchangeable terms. They describe different material properties. The framework identifies three independent characteristics that engineers should evaluate. The first describes the feedstock's origin. A polymer may come from renewable biological resources or from fossil resources. The second describes the polymer itself. Polymer chemistry determines processing behavior and material performance. The third describes degradation behavior. A material may remain stable, biodegradable under specific conditions, or require industrial composting infrastructure. Term Carbon Source Polymer Structure Degradability Examples Plastic Fossil or bio-based Synthetic, long-chain polymer Often persistent PE, PET, PS Bioplastic Bio- or fossil-based Synthetic Varies PLA, bio-PE, PBAT Biopolymer Typically bio-based Produced by organisms or derived from biological... - Published: 2026-10-14 - Modified: 2026-10-14 - URL: https://www.plasticsengineering.org/2026/10/inside-the-analytical-challenges-of-measuring-microplastics-012486/ - Categories: Editor's Choice Technical Paper, Education & Training, Industry, Materials, Microplastics, PET, Polyamide, Polyethylene, Polyolefins, Polypropylene, Testing & Analysis, Trending Measuring microplastics requires reliable detection, contamination control, validated methods, and reproducible analytical results. Measuring microplastics requires reliable detection, contamination control, validated methods, and reproducible analytical results. Researchers studying microplastics face challenges that go beyond simply finding small plastic particles. They must distinguish plastics from thousands of non-plastic particles, prevent contamination during sampling and analysis, select methods with appropriate size limits, and interpret results using defensible statistical approaches. You can also read: Microplastics and Nanoplastics: Hard to See, Harder to Stop These challenges intensify as particle size decreases. As plastics fragment, particle numbers can increase substantially at smaller size ranges. At the same time, smaller particles become harder to separate from environmental matrices and more difficult to identify with sufficient chemical specificity. The Tradeoff Between Speed and Sensitivity Infrared spectroscopy is widely used in microplastics research because it can identify polymers non-destructively. However, faster analysis does not always mean better detection. A Dow-led study evaluated laser direct infrared spectroscopy (LDIR) using a discrete-frequency, image-guided approach. Instead of collecting full spectral information across the entire sample area, the system first scans selected infrared frequencies to locate likely particles. It then collects spectra only from those targets. This strategy reduces the time spent analyzing background material and non-target particles, improving overall analytical throughput. That speed gain, however, depends on how well the selected scanning conditions distinguish target particles from the surrounding matrix. Under several conditions, the researchers identified more than 90% of spiked polyethylene particles larger than 20 µm. They also detected about 94% of PMMA particles between 5 and 20 µm with an appropriate substrate... - Published: 2026-10-14 - Modified: 2026-10-13 - URL: https://www.plasticsengineering.org/2026/10/automotive-plastic-waste-pyrolysis-produces-diesel-range-oil-012337/ - Categories: Automotive & Transportation, Business, Circular Economy, Composites, Durables, Editor's Choice Technical Paper, Energy Generation, Industry, Materials, Polyolefins, Process, Recycling, Recycling, Resins, Sustainability, Thermoplastics, Trending - Tags: ABS, Advanced Recycling, Automotive plastics, Chemical Recycling, Circular Economy, plastic recycling, plastic waste, Polyethylene, Polypropylene, pyrolysis, sustainable materials Research into optimizing the pyrolysis of automotive plastic waste demonstrates the potential to produce oils with properties approaching those of commercial diesel. Research into optimizing the pyrolysis of automotive plastic waste demonstrates the potential to produce oils with properties approaching those of commercial diesel. Recycling plastics from end-of-life vehicles (ELVs) is an important part of improving resource recovery and supporting more circular use of plastics. Among the available technologies, pyrolysis has emerged as a promising route for recovering fuels and chemicals from waste polymers. The process thermally decomposes plastics at elevated temperatures without oxygen, breaking polymer chains into liquid, gaseous, and solid products. Previous studies have shown that pyrolysis can convert common automotive plastics such as low-density polyethylene (LDPE), high-density polyethylene (HDPE), and polypropylene (PP) into valuable hydrocarbons at relatively high yields. However, much of the existing research focuses on automotive shredder residue, a heterogeneous mixture containing plastics, metals, textiles, and other materials. You can also read: Upcycling Polyolefins into Jet Fuel Components That leaves less information about how plastics recovered directly from components such as dashboards, bumpers, and headlamps behave during pyrolysis. Automotive plastic waste (APW) can also contain mineral fillers, flame retardants, fiberglass, and other additives that affect degradation behavior and product composition. Catalysts can improve pyrolysis efficiency by accelerating reactions, altering product distributions, and potentially reducing required temperature or residence time. Commercial zeolites have been widely studied, but lower-cost clay-based alternatives are drawing increasing interest. Among them, pillared clays modified with metals such as iron, titanium, or zirconium have shown potential to increase liquid yields and influence the formation of fuel-range hydrocarbons. Iron-modified clays are particularly attractive because they... - Published: 2026-10-13 - Modified: 2026-10-09 - URL: https://www.plasticsengineering.org/2026/10/composites-growth-faces-a-lightweighting-cost-barrier-012285/ - Categories: Automotive & Transportation, Business, Composites, Compounding, Industry, Materials, Mixing & Blending, People, Process, Results, Strategy, Thermoforming, Thermosets, Trending Automotive composites demand is rising, but high CAPEX, carbon fiber costs, and labor shortages limit who can scale lightweighting. Automotive composites demand is rising, but high CAPEX, carbon fiber costs, and labor shortages limit who can scale lightweighting. A Growing Market with a Heavy Price Tag The automotive composites market stands at USD 12. 18 billion in 2025. For automotive projects, it is projected to reach USD 25. 83 billion by 2034, at a 10. 76% CAGR. Electric vehicle platforms drive much of that growth. Yet a structural tension defines the sector today. Achieving a 10% weight reduction typically raises manufacturing costs by over 30%. Research published at MENEC 2025 describes this as a “lightweight-cost-performance paradox. ” That tradeoff sits at the heart of composites’ commercial challenge. You can also read: What the EV Boom Means for Plastics The opportunity remains undisputed. Plastics Engineering values the global carbon fiber composites market at USD 21. 58 billion in 2023. Analysts project it will reach USD 37. 41 billion by 2032, at a 6. 3% CAGR. Automotive imports of CFRP components rose over 20% in 2025. Coherent Market Insights credits EV platform growth and lightweighting mandates as primary drivers. Yet growth projections tell only part of the story. The cost structure behind these figures determines who benefits. The automotive composites market more than doubled between 2025 and 2034, rising from USD 12. 18 billion to USD 25. 83 billion. EV platform expansion and tightening emissions standards drive the bulk of that growth. Courtesy of Towards Automotive. The CAPEX Barrier That Divides the Field Processing fiber-reinforced composites demands specialized equipment and highly... - Published: 2026-10-12 - Modified: 2026-10-12 - URL: https://www.plasticsengineering.org/2026/10/pfas-compliance-uncertainty-grows-for-medical-device-makers-012450/ - Categories: Additives & Colorants, Editor's Choice Technical Paper, Education & Training, Elastomers, Industry, Materials, Medical, People, PFAS, Polyolefins, Regulation, Resins, Sustainability, Thermoplastics Many medical devices rely on fluoropolymers, and evolving PFAS regulations are creating new compliance and supply-chain challenges. Many medical devices rely on fluoropolymers, and evolving PFAS regulations are creating new compliance and supply-chain challenges. As regulators increase scrutiny of per- and polyfluoroalkyl substances (PFAS), medical device manufacturers face growing compliance uncertainty. Fluoropolymers are used in coatings, packaging, insulation, tubing, guidewires, implants, and other medical-device components because they provide durability, lubricity, chemical resistance, and biostability. You can also read: EU PFAS Restriction Update: ECHA Consultation in 2026 Replacing these materials is difficult because few commercially available alternatives provide the same combination of properties. In addition, changing a material can trigger extensive R&D, manufacturing adjustments, supplier qualification, and regulatory review. In Europe, a broad PFAS restriction proposal under REACH covers more than 10,000 substances and remains under evaluation. ECHA’s scientific committees have supported an EU-wide restriction with targeted derogations, including consideration of medical-device uses where alternatives may not yet be available. The medical and pharmaceutical industry represented 7% of PFAS consumption in the European Union in 2020. Figure courtesy of Impact of the European proposal to restrict PFAS on modern medical technology and treatment options. Operational Transitions Meeting new regulatory requirements may require manufacturers to redesign products, qualify alternative materials, modify production processes, and retrain employees. Procurement strategies may also need to change as companies seek greater transparency about PFAS content throughout their supply chains. These transitions can be costly and time-consuming, particularly for products that require extensive validation before manufacturers can introduce material changes. Impact on Device Availability Limited availability of suitable alternatives has raised concerns about whether... - Published: 2026-10-12 - Modified: 2026-10-12 - URL: https://www.plasticsengineering.org/2026/10/how-back-panel-packaging-design-can-build-brand-loyalty-012251/ - Categories: Business, Design, Editor's Choice Technical Paper, Flexible Packaging, Food Packaging, Industry, Packaging, People, Sustainability, Trending Back and side panels combine storytelling, regulatory information, and design to strengthen packaging communication and build brand loyalty. Back and side panels combine storytelling, regulatory information, and design to strengthen packaging communication and build brand loyalty. A consumer and a package share an intimate moment that few brands design with the same intention they reserve for the front. It arrives once the product is home, resting on a counter or held in a hand, and the person turns the container to read what's on the back. That daily gesture, repeated millions of times, opens a conversation that decides whether a second purchase happens. You can also read: Why Emotional Packaging Matters to Younger Consumers Calling the side and back surfaces secondary is a habit of language that underestimates their strategic weight. Panels of dialogue describe them better. The front competes for a glance on the shelf with seconds to spare. The reverse has minutes, in an intimate setting free of retail pressure. The Space Where Loyalty Is Decided Creative investment concentrates historically on what gets seen first, since the shelf demands stopping power. Once the product leaves the store, the back and side panels take over, and repurchase is built there. Brands that understand this treat the reverse as an editorial channel. Innocent printed a small humorous line at the base of a carton suggesting the consumer open it from the other side, a complicit gesture placed in a zone most brands consider purely functional. Oatly announces its regulatory panel as "The Boring (but very important) Side" and invites readers to turn the carton, converting a legal obligation... - Published: 2026-10-09 - Modified: 2026-10-06 - URL: https://www.plasticsengineering.org/2026/10/liquid-crystal-film-reduces-ghost-images-in-automotive-displays-012245/ - Categories: Adhesives, Automotive & Transportation, Auxiliaries, Design, Elastomers, Equipment, Film, Industry, Materials, People, Process, Sensors, Thermoplastics, Trending A double-layer liquid crystal polymer film reduces ghost images in automotive AR-HUDs while improving reflectivity and maintaining windshield transparency. A double-layer liquid crystal polymer film reduces ghost images in automotive AR-HUDs while improving reflectivity and maintaining windshield transparency. Automotive head-up displays (HUDs) use windshield display technology, where the windshield reflects light from a picture generation unit to form a virtual image the driver can see. Researchers state that the global HUD market will reach USD 15. 26 billion by 2030, growing at a compound annual growth rate of 15. 7% from 2023 to 2030. You can also read: Polymer Aerogels for Advanced Thermal Control But this technology carries a persistent optical flaw: ghost images. Engineers explain this phenomenon as the windshield's front and rear surfaces both reflecting the light, producing a faint duplicate of the image offset from the real one. According to Mercedes-Benz driver tests, a primary-to-secondary image intensity ratio below 100:1 can produce noticeable ghost images in the HUD, potentially compromising driver perception and safety. Manufacturers currently solve this with wedge-shaped windshield glass, which angles the front and rear surfaces, so the two reflections overlap. Manufacturers must custom-fabricate the glass for each vehicle model, and installers cannot retrofit it. It also caps light-source reflectivity below 20% to preserve enough environmental light transmittance for safe driving, wasting the projector's energy. A Retrofittable Alternative Researchers propose a thin, flexible liquid crystal polymer film that attaches directly to any existing windshield's interior surface, no custom glass required. The film stacks two LC layers. The outer layer is a cholesteric LC coating that reflects left-handed circularly polarized light from the PGU... - Published: 2026-10-08 - Modified: 2026-10-06 - URL: https://www.plasticsengineering.org/2026/10/pigment-loading-shapes-thermochromic-plastic-recyclability-012238/ - Categories: Additives & Colorants, Automotive & Transportation, Circular Economy, Design, Durables, Editor's Choice Technical Paper, Extrusion, Food Packaging, Industry, Injection Molding, Materials, Mixing & Blending, Packaging, Polyethylene, Polyolefins, Polypropylene, Process, Recyclate, Recycling, Recycling, Sustainability, Thermoforming, Thermoplastics, Trending - Tags: Polypropylene, recyclability Mechanical recycling can change the color response, surface quality, and mechanical performance of thermochromic polypropylene used in smart packaging. Mechanical recycling can change the color response, surface quality, and mechanical performance of thermochromic polypropylene used in smart packaging. In temperature-sensitive packaging, color can do more than support branding. A thermochromic package can indicate when a product crosses a defined temperature threshold during storage, transport, or use. For food packaging, this optical response could support cold-chain monitoring without electronics, labels, or external readers. You can also read: Setting the Tone with Functional Pigments Mechanical recycling complicates that promise. A color-changing polypropylene package may perform well during first use, but circular design raises a harder question about functional durability. Recent work tested whether food-grade polypropylene with thermochromic pigment could retain its optical signal after five mechanical recycling cycles involving melting, molding, and grinding. The study evaluated optical behavior, thermal response, mechanical performance, and surface morphology in blends containing 0%, 2%, and 8% thermochromic pigment. Color Becomes a Performance Variable Conventional color matching verifies whether a molded part meets visual specifications. Thermochromic systems add a performance criterion. The material must shift color at the target temperature and maintain sufficient contrast for visual or automated detection. That requirement turns color into a functional material response. The team selected a commercial thermochromic masterbatch with a nominal transition near 41 °C and blended it into food-grade nucleated polypropylene. The three compositions included neat PP, PP with 2% thermochromic pigment, and PP with 8% thermochromic pigment. Each formulation went through injection molding, granulation, and remolding to simulate repeated mechanical recycling. This route reflects a practical packaging... - Published: 2026-10-07 - Modified: 2026-10-07 - URL: https://www.plasticsengineering.org/2026/10/polymeric-membranes-improve-gas-separation-in-oil-and-gas-012224/ - Categories: Editor's Choice Technical Paper, Energy Generation, Film, Industry, Materials, People, Polyolefins, Process, Resins, Silicones Polymeric membranes improve gas separation efficiency through tailored permeability, selectivity, and resistance to aging and plasticization. Polymeric membranes improve gas separation efficiency through tailored permeability, selectivity, and resistance to aging and plasticization. Polymer membrane separation is nowadays an energy-efficient industrial alternative for various operations. It plays a key role in gas separation within the O&G industry. Key features include good integration into hybrid systems, low energy consumption, and operational simplicity. Membranes offer modularity and a small footprint compared to conventional alternatives such as amine absorption, cryogenic distillation, or pressure swing adsorption. Although they have not yet displaced conventional technologies, membranes improve overall system economics. You can also read: High-Performance Membranes Made from Plastic Waste These advantages have driven their adoption in applications including the purification, recovery, and conditioning of streams in O&G facilities. These streams contain acid gases, hydrogen, light hydrocarbons, water, and volatile organic compounds. Performance depends on solubility, diffusion, and polymer structure, as well as operational phenomena such as plasticization and aging. Polymer engineering adjusts membrane performance through physicochemical molecular design and morphology control. Transport Fundamentals In dense membranes, the solution-diffusion model dominates and comprises three stages: sorption, diffusion, and desorption. First, gas sorption occurs at the feed surface. Then diffusion occurs through the polymeric volume, and lastly desorption occurs on the low-pressure side. Researchers express permeability P as the product of diffusivity D and solubility S. The overall behavior results from the combination of the penetrant’s thermodynamic affinity and kinetic mobility. This formulation explains why highly condensable gases, such as CO₂, typically exhibit higher solubility in polymers. Meanwhile, small, less condensable molecules may... - Published: 2026-10-06 - Modified: 2026-10-06 - URL: https://www.plasticsengineering.org/2026/10/apoorva-kulkarni-astm-d8646-aquatic-biodegradation-012332/ - Categories: Circular Economy, Editor's Choice Technical Paper, Education & Training, Flexible Packaging, Food Packaging, Industry, Materials, Microplastics, Packaging, Polyolefins, Process, Recyclate, Regulation, Resins, Sustainability, Testing & Analysis, Thermoplastics, Trending - Tags: Biodegradable Plastics Apoorva Kulkarni’s doctoral research helped shape ASTM D8646-26, which estimates temperature-dependent biodegradation behavior in aquatic environments. Apoorva Kulkarni’s doctoral research helped shape ASTM D8646-26, which estimates temperature-dependent biodegradation behavior in aquatic environments. Marine biodegradation tests help researchers measure whether plastics break down under controlled laboratory conditions and how much. However, another question remains harder to answer: how long might those materials persist once they reach colder aquatic environments? ASTM D8646-26 addresses that gap by adding a kinetic framework that accounts for temperature when interpreting biodegradation results. Instead of treating biodegradation as one static result, the methodology estimates biodegradation time within an experimentally tested temperature range. For Apoorva Kulkarni, senior research engineer at Saint-Gobain, that methodology began with an unexpected question during her doctoral research. Apoorva Kulkarni completed her PhD under Prof. Ramani Narayan, with research that helped shape ASTM D8646-26 for aquatic biodegradation testing. “I started my work with no intention of developing an ASTM methodology,” Kulkarni said. Instead, she noticed results that did not make sense, asked why, and followed the science toward standard development. You can also read: How to Test for Chemical Resistance in Plastic Components. Inconsistent Data Raised a Bigger Question Kulkarni’s doctoral research included developing value-added applications using biobased polymers, including starch, cellulose, PLA, and PHBV-type materials. While comparing her biodegradation results with published studies, she noticed substantial variability among results for similar polymers. Therefore, she examined the experimental conditions more closely and found that researchers often conducted tests at different temperatures. However, many studies did not systematically control or evaluate temperature as a factor affecting biodegradation rate. That observation led... - Published: 2026-10-05 - Modified: 2026-10-05 - URL: https://www.plasticsengineering.org/2026/10/spe-microplastics-forum-will-bring-plastics-experts-to-baltimore-012299/ - Categories: Circular Economy, Education & Training, Industry, Materials, Microplastics, People, Polyamide, Polyethylene, Polyolefins, Polypropylene, Resins, Sustainability, Thermoplastics The SPE Microplastics Forum takes place in Baltimore, Maryland, on Oct. 20–21, 2026, covering detection, regulation, and solutions. The SPE Microplastics Forum takes place in Baltimore, Maryland, on Oct. 20–21, 2026, covering detection, regulation, and solutions. Industry Insights Across the Product Lifecycle Microplastics have become a growing focus of research, regulation, and public concern because they persist in the environment. As a result, plastics professionals need reliable technical information to understand risks, requirements, and possible solutions. The SPE Microplastics Forum gives attendees a focused space to explore these issues with experts from industry and academia. The two-day, solution-oriented forum will help professionals gain clarity on microplastics management, prevention, detection, and recovery. You can also read: Microplastics and Nanoplastics: Hard to See, Harder to Stop The program will also connect scientific research with practical industry needs. This matters because companies increasingly need to evaluate microplastics across design, production, use, and end-of-life stages. For professionals working in sustainability, compliance, R&D, engineering, manufacturing, or materials, the forum offers a practical way to stay informed. It also supports better decision-making as regulatory expectations and technical capabilities continue to evolve. Key Forum Topics The Microplastics Forum will feature talks from subject matter experts, industry leaders, and technology providers. Together, these sessions will address the scientific, regulatory, and technical dimensions of microplastics. Key topics include: Microplastics as a scientific and regulatory topic: Attendees will explore new insights and technologies that can help organizations adapt to a rapidly changing regulatory environment. Detection, quantification, and characterization methods: Speakers will examine how new analytical methods are advancing microplastics research and influencing regulation. Strategies to manage and prevent... - Published: 2026-10-02 - Modified: 2026-09-24 - URL: https://www.plasticsengineering.org/2026/10/better-plastic-recycling-starts-with-better-collection-012229/ - Categories: Bioplastics, Business, Circular Economy, Design, Education & Training, Equipment, Flexible Packaging, Food Packaging, Industry, Materials, Medical, Packaging, People, PET, Polyethylene, Polyolefins, Polypropylene, Process, Recyclate, Recycling, Recycling, Resins, Strategy, Sustainability, Thermoplastics, Trending Better collection systems can reduce contamination and improve the quality of recycled plastic feedstock before sorting, washing, and extrusion begin. Better collection systems can reduce contamination and improve the quality of recycled plastic feedstock before sorting, washing, and extrusion begin. Every plastics engineer knows that poor raw material produces poor products. Recycling follows the same rule. Yet the industry continues investing in better sorters, smarter reactors, and more efficient recycling processes while overlooking the step that determines feedstock quality before a truck ever leaves the curb. You can also read: Recovering High-Purity PC/ABS from End-of-Life Vehicles Walk through a modern materials recovery facility, and you will find near-infrared sorters, robotic pickers, advanced washing systems, and increasingly sophisticated recycling technologies. Those innovations have expanded what recycling plants can recover. They cannot recover the value lost when contaminated materials enter the process. The greatest opportunity to improve recycled plastics may no longer sit inside the recycling plant. It may begin at the collection bin. Feedstock Quality Begins With Collection The OECD estimates that the world generated 353 million metric tons of plastic waste in 2019. Only 15% entered the collection system for recycling, and recycling facilities ultimately converted just 9% into secondary materials. Every food-soiled film, misplaced PVC bottle, mixed polymer, or contaminated package lowers the value of the material stream before shredding, washing, or extrusion ever begins. More than fifteen years of research has come to the same conclusion. Hopewell, Dvorak, and Kosior first identified contamination and polymer mixing as major barriers to closed-loop recycling. Ragaert and colleagues later showed that contamination accelerated degradation during repeated processing, while Eriksen and co-workers... - Published: 2026-10-01 - Modified: 2026-09-24 - URL: https://www.plasticsengineering.org/2026/10/active-biopolymer-films-target-food-oxidation-and-spoilage-012217/ - Categories: Bioplastics, Business, Circular Economy, Design, Education & Training, Film, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, Polyethylene, Process, Regulation, Resins, Sustainability Reinforced active bioplastics combine mechanical strength, moisture resistance, and antioxidant performance to extend food shelf life. Reinforced active bioplastics combine mechanical strength, moisture resistance, and antioxidant performance to extend food shelf life. Food packaging engineers face a critical dilemma: traditional petrochemical films damage the environment, while standard bioplastics fail to prevent premature microbial and physicochemical spoilage. To solve this industrial challenge, polymer chemists now extrude reinforced, active biopolymer matrices that manipulate internal atmospheres, scavenge reactive oxygen species, and physically protect perishable goods from distribution damage. You can also read: PVOH for Oxygen-Sensitive Food Packaging Extruding Reinforced Structural Matrices Standard bioplastics often fail under commercial distribution stresses. Pure starch films are extremely brittle and absorb moisture, making them unsuitable for industrial logistics. To address this fragility, packaging researchers extruded flexible films from Amazonian cassava starch. Engineers reinforced this base polymer matrix with plantain leaf microfibers, beeswax, and low-density polyethylene (LDPE) microparticles. Thermoplastic starch (TPS) can be a viable alternative to traditional plastics because it biodegrades rapidly under ambient conditions. Courtesy of Development and Characterization of Reinforced Flexible Packaging Based on Amazonian Cassava Starch Through Flat Sheet Extrusion. This hybrid formulation stabilizes the molecular structure during flat sheet extrusion. The physical inclusion of rigid microfibers and flexible LDPE particles actively blocks crack propagation along the polymer backbone by dispersing kinetic energy during impacts. Meanwhile, the beeswax fills microscopic voids within the starch matrix and repels ambient humidity, preserving the internal mechanical properties. Manufacturers can utilize these reinforced materials to create robust wrappers for dry goods. These composite films rival petrochemical packaging in mechanical durability, meaning facilities can run... - Published: 2026-09-30 - Modified: 2026-09-24 - URL: https://www.plasticsengineering.org/2026/09/thermoplastic-vulcanizates-expand-rubber-processing-options-012208/ - Categories: Automotive & Transportation, Building & Construction, Compounding, Editor's Choice Technical Paper, Education & Training, Elastomers, Electrical & Electronics, Industry, Materials, Process, Sustainability, Trending Engineers optimize ethylene propylene diene monomer (EPDM) and silicone thermoplastic vulcanizates to combine high elasticity with efficient thermoplastic processing for industrial applications. Engineers optimize ethylene propylene diene monomer (EPDM) and silicone thermoplastic vulcanizates to combine high elasticity with efficient thermoplastic processing for industrial applications. Engineers struggle to manufacture materials that retain rubber elasticity while maintaining the rapid processing speeds of thermoplastics. Traditional elastomers lose their moldability once cured, limiting recyclability and driving up production costs. Materials scientists solved this problem by engineering thermoplastic vulcanizates (TPVs). By dynamically vulcanizing an elastomer inside a molten thermoplastic matrix under high shear, developers lock in a phase-inverted microstructure. This physical mechanism creates a dispersed, elastic sea-island morphology that flows like plastic but recovers like crosslinked rubber. You can also read: Teknor Apex Adds TPVs With High Recycled Content Mastering EPDM and Polypropylene Ratios Researchers analyzed how the ratio of ethylene propylene diene monomer (EPDM) to polypropylene (PP) drives TPV mechanical performance. To achieve optimal performance, manufacturers must disperse the rubber phase to reach a maximum packing fraction near 0. 80. This fine dispersion directly controls compression set, the ability of a seal to recover its original shape. Industry standards demand a compression set of 30% or below after enduring a 25% strain at 100 °C for 24 hours. Developers found that curing chemistry, whether using dicumyl peroxide (DCP) or phenolic resins (Resol), does not change this elastic recovery compared to pure EPDM. However, engineers can boost the tensile strength of high-rubber blends (20% PP) by introducing carbon black. When fabricators use radical peroxide curing, carbon black localizes at the polymer interface and acts as a structural... - Published: 2026-09-29 - Modified: 2026-09-24 - URL: https://www.plasticsengineering.org/2026/09/digitalization-makes-lca-more-accurate-and-traceable-012163/ - Categories: Circular Economy, Design, Education & Training, Flexible Packaging, Food Packaging, Industry, Industry 4.0, Medical, Packaging, People, Process, Semi-Finished Products, Software, Sustainability, Trending Digital tools bring real-time data, traceability, and automated updates to LCA, improving environmental decisions across the value chain. Digital tools bring real-time data, traceability, and automated updates to LCA, improving environmental decisions across the value chain. From Static Data to Dynamic LCA Life cycle assessment, or LCA, has become one of the most widely used tools for evaluating environmental impacts across a product’s value chain. Now, digitalization is pushing the methodology toward more dynamic and data-rich applications. You can also read: Digital Product Passports: Revolutionizing Transparency and Sustainability Traditional LCAs often rely on large datasets from databases that remain static or update only at set intervals. Digital tools can change that model by connecting assessments with operational data generated across production, logistics, energy use, and waste management. As a result, companies can move from largely manual studies toward more dynamic assessments that reflect changing conditions more quickly. Digitalized LCAs can also incorporate more granular measurements from production systems. This allows companies to account for variables such as changes in electricity sourcing, transportation routes, production efficiency, and specific recycling pathways. The result is not necessarily a completely real-time LCA in every application. However, more frequent and automated data updates can improve the accuracy, relevance, and usability of environmental assessments. Digital Product Passports Expand Traceability Digitalization can also connect LCA results with emerging digital product passport systems. Companies could use these connections to support carbon-footprint reporting, recycled-content verification, chemical transparency, and other sustainability metrics. More traceable information can strengthen decision-making for manufacturers, suppliers, customers, and policymakers. This integration also makes environmental information easier to update as production conditions change. Instead... - Published: 2026-09-28 - Modified: 2026-09-24 - URL: https://www.plasticsengineering.org/2026/09/why-halogen-free-flame-retardants-still-challenge-compounders-012160/ - Categories: Additives & Colorants, Compounding, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Industry, Materials, People, PFAS, Process, Regulation, Resins, Sustainability, Trending Halogen-free flame retardants improve fire safety, but compounders still balance processing, durability, smoke, and electrical performance. Halogen-free flame retardants improve fire safety, but compounders still balance processing, durability, smoke, and electrical performance. Cleaner flame-retardant systems now lead product development. But processors still face real trade-offs. Fire safety, throughput, and durability pull in different directions. Better formulations will need more than good chemistry. The way you build the formula will matter most. You can also read: Flame-Resistant Polymers for Space Safety and Aerospace Use Regulation Pushes Beyond Simple Substitution Regulators no longer look at flame retardants alone. They now study whole chemical families and exposure profiles. The European Chemicals Agency has raised scrutiny of brominated systems. It also targets some organophosphorus options. This shift has changed priorities across plastics and wire applications. Compounders now design systems around migration resistance, smoke control, and recyclability. Electrical stability over time also matters. Systems must still pass UL 94 ratings, CTI tests, and hydrothermal durability checks. Regulatory pressure now extends beyond brominated chemistries toward broader assessments of flame-retardant sustainability, recyclability, and long-term environmental impact. Courtesy of The European Regulatory Strategy for flame retardants. These pressures have reshaped the halogen-free flame-retardant market. Suppliers now push phosphorus–nitrogen blends, mineral synergists, and intumescent designs. Single-additive solutions are losing ground fast. A study in Environment International sent a clear warning. Not all halogen-free systems carry equal environmental or toxicological profiles. Wire and Cable Remains the Toughest Test Low-smoke zero-halogen cable compounds reveal the sector's core conflict. Mineral hydrates improve fire safety and cut toxic gas output. But they often need extremely high loading levels. Research... - Published: 2026-09-25 - Modified: 2026-09-22 - URL: https://www.plasticsengineering.org/2026/09/the-sensorial-container-designing-packaging-for-all-five-senses-012190/ - Categories: Business, Design, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, People, Polyolefins, Resins, Silicones, Sustainability, Trending Sensory packaging uses sight, touch, sound, smell and taste to shape brand perception and create memorable product experiences. Sensory packaging uses sight, touch, sound, smell and taste to shape brand perception and create memorable product experiences. We meet brands with our hands long before we meet them with our reasoning. A cap turns, a foil resists, a surface cools the fingertips, and an opinion forms. Packaging occupies this intimate territory every day of a product's life. Understanding it as a sensorial system opens a design space most categories have barely entered. You can also read: Why Emotional Packaging Matters to Younger Consumers Perception is emotional before it becomes analytical. A container speaks through weight, temperature, sound, and resistance, and those impressions settle into memory faster than any written claim. Aesop's amber bottles feel apothecary serious in the palm. Illy's pressurized tin releases a sigh of trapped aroma that certifies freshness without a word. These experiences are designed with the same intention a brand brings to its logotype, and they earn loyalty through the body itself. Five Channels, One Idea Sight remains the entry point, carrying shape, color, and structure into a half second of shelf recognition. Touch settles the question of quality, since surface and rigidity tell us whether something is precious or disposable. Sound performs verification: a seal breaking, a pump priming, a wrapper unfolding. Smell primes anticipation and colors everything that follows. Taste answers to form, because the container decides portion, flow, and bite. Each channel can express the same idea in its own vocabulary. Babybel builds a three-step ritual into its wax shell, where pulling... - Published: 2026-09-24 - Modified: 2026-09-21 - URL: https://www.plasticsengineering.org/2026/09/circular-automotive-foams-recyclable-tpe-for-soft-touch-parts-012126/ - Categories: Automotive & Transportation, Circular Economy, Education & Training, Equipment, Foam Processing, Industry, Injection Molding, Materials, Process, Sustainability, Thermoplastics, Trending Foamed TPE and PP could replace non-recyclable automotive soft-touch structures while reducing weight and increasing recycled content. Foamed TPE and PP could replace non-recyclable automotive soft-touch structures while reducing weight and increasing recycled content. Upcoming European regulations require automotive applications to incorporate at least 15% post-consumer recycled plastic by 2032, and 25% by 2036. With this increasing pressure, there is a need to look for circular material solutions for end-of-life vehicles (ELV). You can also read: Polypropylene Recycling from Disposable Face Masks Recyclable TPE for Soft-Touch Parts Foams, in particular, are widely used in soft-touch applications inside the vehicle and are the focus of several new developments. One approach aims to replace thermoset foams and composite foamed structures with thermoplastic, recyclable alternatives. A research project at the IKV, Institute of Plastics Processing in Aachen, Germany, aims to develop circular foamed products for soft-touch applications. In this case, the objective is the substitution of non-recyclable composites through foamed TPE (thermoplastic elastomers). Conventionally, soft-touch components are made from a thermoplastic carrier (such as PP or fiber-reinforced PP), a polyurethane foam, and a decorative layer made of PVC or leather. The project “Foam2Cycle”, currently under development and funded by the German Federal Ministry for Economic Affairs and Energy, investigates a thermoplastic structure that combines structural PP with TPE, produced via foam injection molding using physical foaming agents. A new process developed at the IKV targets the production of a mono-material soft-touch thermoplastic component. This alternative replaces composite structures, and the foaming is achieved via foam injection molding with an expansion of the mold cavity. Image courtesy of IKV. IKV has... - Published: 2026-09-23 - Modified: 2026-09-21 - URL: https://www.plasticsengineering.org/2026/09/new-german-project-uses-ai-and-batch-data-to-improve-pcr-quality-012150/ - Categories: Artificial Intelligence, Education & Training, Equipment, Industry, Industry 4.0, Materials, Process, Recyclate, Recycling, Recycling, Resins, Sensors, Software, Sustainability, Thermoplastics, Trending AI sorting, data-driven compounding, and digital traceability improve PCR purity, consistency, and confidence across recycling value chains. AI sorting, data-driven compounding, and digital traceability improve PCR purity, consistency, and confidence across recycling value chains. One of the main challenges in plastics circularity is producing large volumes of clean, high-purity waste streams. A new German project, called SoliD-Q, is exploring how AI-assisted sorting can work alongside data-driven compounding and digital quality verification to improve recycled-material performance. Object-Based Sorting Targets Higher-Quality PCR Sorting by polymer family alone is not always enough. Two products may both be made from HDPE, for example, but their previous applications, additives, contamination levels, and processing histories can affect recyclate quality. For this reason, the project focuses on developing waste streams based not only on resin type, but also on product application. At the same time, it captures information from sorting, processing, and quality-control stages to improve traceability across the recycling chain. You can also read: Computational Approaches to Fast-Track Material Development This approach is described as object-based sorting. Instead of separating only by polymer type, the system identifies specific products and directs them into more targeted recycling streams. By combining these sorting decisions with process and quality data, the project aims to preserve material purity while creating more consistent recyclate grades. From Waste to Data SoliD-Q integrates sorting, processing, and quality information across the value chain. The goal is to produce high-purity PCR materials with batch-specific properties and a corresponding digital fingerprint. Three partners contribute different technologies to the project. WeSort. AI is developing AI-based object recognition to sort plastic waste according to product... - Published: 2026-09-22 - Modified: 2026-09-18 - URL: https://www.plasticsengineering.org/2026/09/chemical-safety-in-plastics-2026-tackles-pfas-reformulation-012145/ - Categories: Additives & Colorants, Aerospace, Automotive & Transportation, Electric Vehicles, Electrical & Electronics, Industry, Materials, Medical, Packaging, People, PFAS, Sustainability, Trending PFAS restrictions are forcing plastics suppliers to reformulate high-performance materials without sacrificing heat, friction, or durability. PFAS restrictions are forcing plastics suppliers to reformulate high-performance materials without sacrificing heat, friction, or durability. Regulators are pushing the industry toward fluorine-free materials, while engineers still need plastics that withstand heat, voltage, friction, and aggressive chemicals. This tension has created one of the industry's most difficult reformulation challenges. The Hidden Dependence on PFAS PFAS restrictions now extend well beyond fluoropolymer resins to include processing aids, surfactants, lubricants, and specialty additives used throughout plastics manufacturing. According to the OECD's fluoropolymer lifecycle analysis, many of these fluorinated additives perform several functions at once. They can reduce melt fracture and die build-up while also improving weatherability and electrical stability. Finding a single alternative that delivers the same combination of benefits remains difficult. You can also read: What’s All The Fuss About PFAS? Polyolefin extrusion shows this most clearly. Fluoropolymer processing aids have long prevented surface defects in blown-film production. Suppliers now offer silicone-based, hyperbranched, and boron nitride options. Yet processors still report trade-offs in throughput, surface quality, and long-run production. The problem goes beyond processing. Fluorinated additives also support low friction, chemical resistance, plasma stability, and dielectric reliability. SPE technical discussions and patent activity from Ampacet, BASF, and Avient show a common pattern. Fixing one problem often creates another. A new formula may meet compliance rules but lose durability or heat stability. Regulators increasingly examine the full lifecycle of fluorinated materials, from manufacturing emissions to waste management and environmental persistence. That scrutiny now shapes material selection and product design decisions. Flame Retardants... - Published: 2026-09-21 - Modified: 2026-09-21 - URL: https://www.plasticsengineering.org/2026/09/similar-settings-different-flow-marks-the-role-of-melt-behavior-012232/ - Categories: Aerospace, Automotive & Transportation, Design, Editor's Choice Technical Paper, Electrical & Electronics, Industry, Injection Molding, Materials, Medical, Polyolefins, Process, Resins, Software, Thermoplastics, Trending Dimensionless analysis links flow-mark formation in polypropylene injection molding to melt relaxation, cavity scale, and the Weissenberg number. Dimensionless analysis links flow-mark formation in polypropylene injection molding to melt relaxation, cavity scale, and the Weissenberg number. Flow marks remain a frequent surface defect in injection-molded components. They typically appear as wave-like streaks or bands on the part surface, often roughly perpendicular to the melt-flow direction. In polypropylene systems, these marks create a serious appearance issue, especially on large, uncoated automotive parts such as bumpers, instrument panels, and door panels. You can also read: Intro to Plastics: Solving Jetting in Injection Molding Conventional troubleshooting often changes injection temperature, injection speed, mold temperature, or molecular characteristics such as molecular weight distribution. However, this approach can become empirical because flow marks do not respond to a single variable in a simple way. A recent study notes that flow marks relate closely to unstable melt behavior at the material flow front, but the full mechanism still lacks a clear conclusion. From Machine Settings to Flow Similarity The study applied dimensional analysis to polypropylene melt flow during injection molding. Instead of treating mold size, melt velocity, relaxation time, temperature, and material interactions separately, the analysis grouped them into dimensionless quantities. The authors classified these quantities into three categories: geometric quantities related to mold shape, material quantities related to melt and mold materials, and physical quantities related to flow. This framework matters because it compares molding conditions through the physics of the flow field rather than through nominal machine settings alone. When mold geometry changes proportionally, while melt material, mold material, and initial temperatures... - Published: 2026-09-19 - Modified: 2026-09-17 - URL: https://www.plasticsengineering.org/2026/09/ai-injection-molding-ecosystem-smarter-together-012191/ - Categories: Industry, Materials, Packaging, Resins, Trending - Tags: Artificial Intelligence, digital twin, Industry 4.0, Injection Molding, Plastics Engineering, Plastics industry, polymer processing, Process Optimization, smart manufacturing The AI Injection Molding Ecosystem is not about predicting the future. It connects materials, simulations, machines, molds, sensors, and AI into a single ecosystem that enables better decisions in real time. The AI Injection Molding Ecosystem is not about predicting the future. It connects materials, simulations, machines, molds, sensors, and AI into a single ecosystem that enables better decisions in real time. The Next Chapter of Injection Molding Has Already Begun For more than forty years, simulation software has helped injection molders answer a critical question before the first shot: What will happen inside the mold? Engineers learned to predict filling patterns, pressure requirements, cooling performance, fiber orientation, shrinkage, and warpage long before making tooling investments. Courtesy of Moldex. Engineers learned to predict filling patterns, pressure requirements, cooling performance, fiber orientation, shrinkage, and warpage long before making tooling investments. Simulation became an essential decision-making tool, reducing development time and minimizing costly trial-and-error activities. You can also read: Digital Twins and Predictive Analytics in Plastics Supply Chains Today, however, the industry stands at the beginning of a new chapter. Artificial Intelligence is transforming not only simulation, but the entire injection molding value chain. What was once a collection of independent technologies is rapidly becoming an interconnected digital ecosystem where software developers, machine manufacturers, material suppliers, start-ups, and producers work together to create a more intelligent manufacturing environment. This transformation is at the heart of the AI Injection Molding Simulation Panel during the 2026 SPE Injection Molding Innovation Summit, where some of the industry's most influential technology providers will discuss what comes next. From Better Simulations to Smarter Engineering Decisions The first wave of digitalization focused on prediction. The next wave focuses on... - Published: 2026-09-18 - Modified: 2026-09-18 - URL: https://www.plasticsengineering.org/2026/09/flexloop-targets-high-purity-recycling-for-flexible-packaging-012132/ - Categories: Business, Circular Economy, Editor's Choice Technical Paper, Education & Training, Film, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Recycling, Resins, Strategy, Sustainability, Thermoplastics, Trending - Tags: Mechanical Recycling Flexloop uses solvent extraction to remove inks, adhesives, odors, and contaminants from flexible films, enabling higher-quality recycled resin. Flexloop uses solvent extraction to remove inks, adhesives, odors, and contaminants from flexible films, enabling higher-quality recycled resin. A new solvent-assisted mechanical recycling process removes inks, adhesives, odors, and other contaminants from flexible packaging. The resulting recyclate can meet demanding requirements for sensitive packaging applications. Procter & Gamble has partnered with Austrian recycling technology supplier Lindner to scale a new recycling technology for flexible packaging. You can also read: The Complexity of Recyclate Solvent Extraction Upgrades Mechanical Recycling The process uses solvent-based extraction to remove contaminants such as odors, inks, adhesives, and other unwanted substances. This additional purification step aims to produce recyclate suitable for sensitive applications, including cosmetics, personal care, and hygiene packaging. Called Flexloop, the technology operates as a modular system that recyclers can integrate into existing Lindner washing and recycling lines. Rather than replacing mechanical recycling, Flexloop extends the process by adding solvent extraction before conventional washing. The solvent removes contaminants without breaking polymer chains or fundamentally altering the material’s chemical structure. This distinction allows the process to preserve more of the polymer’s original properties while improving recyclate purity. Moreover, flexible packaging remains particularly difficult to recycle into equivalent applications. Collection systems often combine different polymers, while inks, adhesives, labels, and other substances can migrate into recycled material during processing. As a result, recyclers frequently direct recovered films toward lower-value applications. Flexloop adds a solvent-based extraction stage before washing in mechanical recycling. The process produces higher-quality recycled resin for sensitive packaging applications. Image courtesy of Lindner Recycling.... - Published: 2026-09-17 - Modified: 2026-09-16 - URL: https://www.plasticsengineering.org/2026/09/why-plastic-additives-matter-for-performance-and-circularity-012138/ - Categories: Additives & Colorants, Aerospace, Automotive & Transportation, Building & Construction, Circular Economy, Compounding, Editor's Choice Technical Paper, Electrical & Electronics, Industry, Materials, Medical, Packaging, Process, Recycling, Recycling, Sustainability - Tags: Polymer Additives Plastic additives enabled global polymer growth, but today they also create new challenges for recycling, compliance, and circular material design. Plastic additives enabled global polymer growth, but today they also create new challenges for recycling, compliance, and circular material design. Additives Turned Resin Into Industry Commodity polymers rarely reached markets in pure form. Manufacturers needed additives to process them reliably and extend their lifespan. V. Marturano and colleagues in Physical Sciences Reviews confirm that additives became essential performance tools, not secondary ingredients. You can also read: Additives in Action: Enhancing Plastic Recycling PVC makes this point clear. Unmodified PVC degrades under heat and processes poorly. Plasticizers added flexibility. Heat stabilizers prevented breakdown during extrusion. Lubricants improved flow, and impact modifiers boosted toughness. Pigments and fillers expanded design options and cut costs. Those formulations opened global markets fast. Flexible PVC entered wire insulation, flooring, medical tubing, and coated fabrics. Rigid grades supported pipes, window profiles, and construction products. SONGWON's technical materials show how stabilizers and plasticizers enabled uses from signage to inflatable products. Compounding then industrialized customization. Twin-screw extrusion systems mixed polymers with additives, fillers, and reinforcements under controlled heat. Patent literature on counter-rotating twin-screw systems shows how compounders managed dispersion while limiting degradation. Stabilization Enabled Polyolefin Expansion Polyolefins faced different problems. Polyethylene and polypropylene processed well, but oxidation and sunlight shortened product life. Antioxidants, phosphites, UV absorbers, and HALS packages fixed those weaknesses. Pfaendner's 2025 historical review in Macromolecular Materials and Engineering traces how antioxidant chemistry advanced beyond early hindered phenols. Those packages protected polymers during extrusion, molding, storage, and outdoor use. The impact went far beyond chemistry. Stabilized polyolefins... - Published: 2026-09-16 - Modified: 2026-09-18 - URL: https://www.plasticsengineering.org/2026/09/in-line-resin-monitoring-targets-recycled-resin-variability-012269/ - Categories: Automotive & Transportation, Auxiliaries, Building & Construction, Business, Circular Economy, Durables, Editor's Choice Technical Paper, Education & Training, Elastomers, Electrical & Electronics, Equipment, Extrusion, Flexible Packaging, Food Packaging, Industry, Industry 4.0, Injection Molding, Materials, Mixing & Blending, Packaging, Polyolefins, Process, Recycling, Recycling, Resins, Sensors, Software, Sustainability, Thermoplastics, Trending Real-time resin diagnostics help processors monitor melt behavior, manage recycled-content variability, and improve plastics quality control. Featured Sponsor Content Real-time resin diagnostics help processors monitor melt behavior, manage recycled-content variability, and improve plastics quality control. An Instrumented Process With One Blind Spot Over the past several decades, plastics processing has become one of manufacturing’s most heavily instrumented sectors. Across injection molding, extrusion, and compounding lines, processors control and record many variables in real time. These include barrel temperature, melt pressure, screw speed, and clamping force. However, one critical variable remains largely unmeasured. Processors still lack continuous visibility into the melt's dynamic state. You can also read: The Complexity of Recyclate Melt viscosity and elasticity shift with composition, molecular weight distribution, and thermal or shear history. These changes can appear between lots, but they can also occur within a single lot. Melt flow index, or MI, remains the industry’s standard quality measurement. However, MI testing happens off-line, in batches, and away from the production run. As a result, most plastics processes still assume that resin entering the die remains uniform. That assumption creates a blind spot, especially as processors use more recycled material. Recycled Resin Makes Variability More Visible Recycled-content mandates now make the cost of this assumption more visible across major end-use markets. The EU End-of-Life Vehicles Regulation, which took effect in August 2026, requires recycled plastics in new vehicles. Starting six years after entry into force, new vehicles must include at least 15% recycled plastic. After ten years, that requirement rises to 25%. Meanwhile, the EU Packaging and Packaging Waste Regulation and similar policies are... - Published: 2026-09-15 - Modified: 2026-09-14 - URL: https://www.plasticsengineering.org/2026/09/how-pcr-pfas-rules-and-epr-are-reshaping-healthcare-foams-012113/ - Categories: Bioplastics, Business, Circular Economy, Education & Training, Elastomers, Industry, Legal Analysis, Materials, Medical, Microplastics, People, PFAS, Polyolefins, Process, Recycling, Recycling, Regulation, Resins, Sustainability, Thermoplastics, Trending - Tags: Healthcare Plastics Healthcare foams face growing pressure from PCR adoption, PFAS restrictions, EPR policies, and circularity goals across medical supply chains. Healthcare foams face growing pressure from PCR adoption, PFAS restrictions, EPR policies, and circularity goals across medical supply chains. Healthcare foams have long been valued for improving patient comfort, protecting medical devices, supporting wound healing, and enhancing infection control. From hospital mattresses and pressure-relief cushions to wound care dressings, prosthetics, and medical packaging, foam materials have become essential to modern healthcare delivery. You can also read: How Recyclability is Redefining Packaging Form and Function. Today, however, healthcare providers are looking beyond performance alone. Sustainability, waste reduction, and regulatory compliance are becoming part of every purchasing and product development discussion across the healthcare, pharma, and medical technology sector This shift is not surprising. The healthcare sector is estimated to contribute approximately 4. 4% of global greenhouse gas emissions, placing increasing pressure on hospitals, medical device manufacturers, and healthcare suppliers to reduce their environmental footprint while maintaining patient safety standards. Healthcare Waste Is Bringing Foam Materials Into Focus Healthcare systems generate significant volumes of waste every year. According to the World Health Organization, approximately 85% of healthcare waste is non-hazardous. Meanwhile, the remaining 15% requires specialized handling because it is considered hazardous. The organization also estimates that healthcare systems administer nearly 16 billion injections worldwide each year. Consequently, disposable healthcare products continue adding significant volumes to global waste streams. Foams represent only one portion of this challenge. However, hospitals, clinics, laboratories, diagnostic centers, research facilities, and medical-device supply chains use them extensively. As healthcare organizations strengthen sustainability commitments, they increasingly examine how... - Published: 2026-09-14 - Modified: 2026-09-09 - URL: https://www.plasticsengineering.org/2026/09/polymer-science-data-gap-012101/ - Categories: Artificial Intelligence, Editor's Choice Technical Paper, Education & Training, Elastomers, Industry, Industry 4.0, Materials, People, Resins, Software, Trending Researchers are addressing polymer data scarcity through AI, high-throughput experiments, simulations, literature mining, and standardized databases. Researchers are addressing polymer data scarcity through AI, high-throughput experiments, simulations, literature mining, and standardized databases. Unlike fields such as metals or semiconductors, polymers lack large, high‑quality datasets. This gap limits the performance of machine learning models and slows material discovery. Researchers are developing strategies to overcome data scarcity and unlock the full potential of AI in polymer research. You can also read: Tooling Digitalization: Knowledge Management A Fragmented Data Landscape Designing new polymers requires navigating a complex space of molecular structures, processing conditions, and resulting properties. These relationships are nonlinear and high‑dimensional, making traditional trial‑and‑error approaches inefficient. More fundamentally, researchers store polymer data across academia, industry, and simulation repositories. These sources rarely follow consistent formats or standards. Researchers report critical properties such as glass‑transition temperature using incompatible measurement standards, and industrial datasets remain proprietary. This fragmentation undermines the generalizability of AI models. It also leaves understudied families, such as vitrimers and conjugated microporous polymers, without sufficient data. Two main challenges limit progress: prohibitive costs and low experimental throughput, and a lack of standardized formats and measurement protocols. Expanding Data Through Smart Generation A key strategy for overcoming data scarcity is to generate new data efficiently. High‑throughput experimentation and active learning enable autonomous discovery cycles in which algorithms suggest experiments that maximize information gain. Closed‑loop platforms that combine robotics, real‑time characterization, and machine learning can rapidly generate self‑consistent datasets. For example, Jurģis et al. built a system for solid electrolyte discovery in which impedance spectroscopy guides experimental selection. Such workflows... - Published: 2026-09-11 - Modified: 2026-09-10 - URL: https://www.plasticsengineering.org/2026/09/sustainability-snapshot-the-lego-group-012106/ - Categories: Bioplastics, Business, Circular Economy, Design, Durables, Editor's Choice Technical Paper, Industry, Injection Molding, Materials, People, PET, Polycarbonate, Polyethylene, Polyolefins, Polypropylene, Process, Recycling, Recycling, Resins, Strategy, Sustainability, Thermoplastics, Toys, Trending - Tags: recycled PET, Recycled plastics LEGO is reducing emissions and expanding the use of renewable, recycled, and mass-balance plastics across its global toy portfolio and supply chain. LEGO is reducing emissions and expanding the use of renewable, recycled, and mass-balance plastics across its global toy portfolio and supply chain. The LEGO Group, arguably the most recognizable toy brand in the world, has established a strong reputation for play since its founding in 1932. A key element of its success lies in exceptional plastic materials and engineering. Its product range primarily consists of injection-molded plastic, including both rigid, durable bricks and soft, flexible elements, collectively known as LEGO elements. You can also read: LEGO drops plan to make its bricks from recycled PET bottles. Since 1963, most LEGO elements have been produced from plastics, specifically acrylonitrile butadiene styrene, or ABS. Over the decades, the combination of imaginative play design and expertly engineered polymers has resulted in nearly perfect plastic toys. The functionality of these products is diverse, encompassing everything from transparent elements and flexible tires to pins and axles. However, as consumers become more aware of sustainability, durable goods like LEGO elements are increasingly scrutinized for their environmental impact. To address this concern while maintaining strict safety and quality standards in mass production, the materials and sustainability teams at LEGO have developed several strategic solutions that incorporate sustainable raw materials and practices. Plastic materials used across LEGO elements, including ABS, HIPS, PA, arMABS, MTPO, and PC, each selected for specific performance requirements. Courtesy of The LEGO Group. With a wide plastics portfolio, LEGO has embarked on a science-backed, ambitious, and public sustainability journey. Their sustainability snapshot highlights past... - Published: 2026-09-11 - Modified: 2026-09-02 - URL: https://www.plasticsengineering.org/2026/09/what-early-plastics-recovery-efforts-got-right-and-wrong-012060/ - Categories: Business, Circular Economy, Elastomers, Industry, Materials, Packaging, People, PET, Polyamide, Polyolefins, Process, Recycling, Recycling, Resins, Results, Strategy, Sustainability, Thermoplastics, Trending - Tags: Design for Recycling Early plastics recycling succeeded with clean, single-resin streams but struggled with contamination, weak markets, and systems not designed for scale. Early plastics recycling succeeded with clean, single-resin streams but struggled with contamination, weak markets, and systems not designed for scale. Clean Streams Worked, Until They Didn’t Early plastics recycling succeeded where materials behaved predictably. Industrial scrap and mono-resin streams offered consistent composition and low contamination. Reprocessors could remelt these materials with limited property loss. You can also read: Plastics 2028: AI, Circularity, and Smart Materials from K-2025 According to Hopewell, Dvorak, and Kosior, plastics recycling always depended on controlling contamination and polymer degradation. Early programs understood this constraint in industrial contexts. They struggled when they applied the same logic to household waste. Post-consumer streams introduced mixed polymers, additives, and residues. These variables disrupted melt flow, reduced mechanical properties, and increased sorting costs. Schyns and Shaver show that even small contaminant levels can degrade recyclate performance. Early systems treated plastics as a uniform waste stream. They functioned as a complex materials system with incompatible chemistries. PET Proved the Model, With Constraints Polyethylene terephthalate became the clearest success case. Deposit systems built clean feedstock streams. Resin-specific collection kept materials consistent. That consistency created viable secondary markets. You can also read: Fluoropolymers Life Cycle and PFAS Contamination But PET recycling also exposed system fragility. PVC contamination degraded PET during processing. It caused discoloration and reduced intrinsic viscosity. National Recovery Technologies filed patents in the 1980s and 1990s. Those patents focused on detecting and removing PVC from PET streams. Later, near-infrared sorting and flake separation increased purity. Companies like TOMRA now use sensor-based sorting.... - Published: 2026-09-10 - Modified: 2026-09-02 - URL: https://www.plasticsengineering.org/2026/09/plastics-logistics-evolves-from-railcars-to-intermodal-systems-012057/ - Categories: Automotive & Transportation, Building & Construction, Business, Circular Economy, Industry, Materials, People, Resins, Sustainability, Trending Plastics logistics evolved from bulk railcars to intermodal systems as trade, regulation, pellet loss, and sustainability reshape resin transport. Plastics logistics evolved from bulk railcars to intermodal systems as trade, regulation, pellet loss, and sustainability reshape resin transport. Railcar logistics formed the foundation of plastics distribution in North America. Producers relied on hopper cars to move large resin volumes efficiently. Companies such as Union Pacific Railroad and BNSF Railway still anchor this system today. You can also read: Inventory Management Trends in Plastic Packaging Railcars Built the Domestic Backbone Rail offers cost advantages and scale for commodity polymers. According to Union Pacific documentation, rail networks connect petrochemical hubs directly to converters and compounders. This infrastructure enabled early market expansion by lowering transport costs and ensuring steady supply. However, this system shows strain. Aging infrastructure and service reliability issues now limit flexibility. Rail also competes with other bulk commodities for capacity. These constraints increasingly clash with modern supply chain expectations for speed and responsiveness. Containers Unlocked Global Reach Intermodal container systems transformed plastics logistics by enabling global exports. U. S. shale-driven polyethylene expansion forced producers to seek overseas markets. Companies such as LyondellBasell and Dow Inc. now depend heavily on containerized shipping. Silo containers and specialized bulk units support this shift. Innovations from firms like Bertschi AG improve contamination control and handling efficiency. These systems allow producers to ship smaller, flexible volumes across diverse routes. Intermodal systems now anchor plastics trade, linking production hubs to global markets while exposing the industry to volatility in ports, containers, and freight networks. Intermodal logistics also supports sustainability goals. Research in Transportation Research Part... - Published: 2026-09-09 - Modified: 2026-09-02 - URL: https://www.plasticsengineering.org/2026/09/ultrasonic-plasticization-targets-the-limits-of-micro-molding-012041/ - Categories: Aerospace, Business, Design, Editor's Choice Technical Paper, Electrical & Electronics, Energy Generation, Industry, Injection Molding, Materials, Medical, Mold & Die Making, Process, Resins, Strategy, Testing & Analysis, Thermoplastics, Trending Ultrasonic plasticization helps micro-molders process small polymer volumes, reduce waste, and improve fine-feature replication in precision parts. Ultrasonic plasticization helps micro-molders process small polymer volumes, reduce waste, and improve fine-feature replication in precision parts. Micro-injection molding continues to target smaller parts, tighter tolerances, and more functional surfaces. This shift raises a key processing challenge. Manufacturers must prepare very small polymer volumes, reduce material waste, and maintain melt control. You can also read: The Art of the Small: Strategies for Success in Micro Molding Ultrasonic plasticization offers one route. Instead of using a conventional screw and heated barrel, the process applies high-frequency vibration to soften a small polymer charge. The approach can reduce residence time, limit shot size, and support the replication of fine microfeatures. That combination matters for medical devices, microfluidics, sensors, and miniature technical parts. In these applications, processors do not only need to fill a cavity. They must also reproduce small surface features with reliable geometry. How Ultrasonic Plasticization Works In ultrasonic micro-injection molding, a sonotrode transmits high-frequency vibration to the polymer feedstock, generating heat through two primary mechanisms. The first is interfacial friction, which occurs at contact points between polymer surfaces, the mold, and the sonotrode. The second is viscoelastic heating, in which the polymer converts mechanical energy into heat through internal deformation under ultrasonic excitation. Together, these mechanisms make feedstock geometry a critical process variable. Shape, packing density, contact area, and compaction behavior influence plasticization rate, melt temperature, and flow development. As a result, the feedstock functions not only as the raw material, but also as an active element in heat generation and... - Published: 2026-09-08 - Modified: 2026-09-01 - URL: https://www.plasticsengineering.org/2026/09/ai-uses-thermal-imaging-to-predict-molded-part-quality-012035/ - Categories: Artificial Intelligence, Automation, Editor's Choice Technical Paper, Education & Training, Equipment, Industry, Injection Molding, Materials, Mold & Die Making, Process, Resins, Sensors, Testing & Analysis, Trending - Tags: Injection Molding Infrared thermography and neural networks help predict injection-molded part quality by analyzing thermal patterns linked to cooling and warpage. Infrared thermography and neural networks help predict injection-molded part quality by analyzing thermal patterns linked to cooling and warpage. Injection molding quality depends on the interaction among material response, processing conditions, mold design, and cooling behavior. Filling, packing, cooling, and solidification inside the mold directly influence key quality indicators, including part mass, tensile strength, and warpage. You can also read: Real-Time Melt Monitoring in Extrusion and Injection Molding Recent research explored infrared thermography as a tool for online quality prediction in injection molding. Researchers captured thermal images of molded parts and trained a convolutional neural network to associate temperature-field patterns with final product quality. Why Thermal Fields Matter Many quality checks still happen after molding, through dimensional measurement, mechanical testing, or visual inspection. These methods can confirm whether a part meets specifications, but they often detect problems only after production has already generated defective parts. By then, the process may have continued under unstable conditions for several cycles. Thermal imaging offers another way to monitor quality by capturing the surface temperature of molded parts shortly after ejection. The temperature field can show how evenly the part cooled and where heat remained longer. Hotter regions or uneven cooling patterns may point to differences in packing, shrinkage, crystallization, or residual stress development. Thermal imaging adds value because it captures a process signal that changes with part quality. A stable temperature pattern can indicate consistent cooling, while unusual hot spots or uneven cooling may signal problems before standard inspection catches them. This makes... - Published: 2026-09-07 - Modified: 2026-08-31 - URL: https://www.plasticsengineering.org/2026/09/catalytic-pathways-target-chemical-circularity-for-polyolefins-012015/ - Categories: Business, Circular Economy, Education & Training, Energy Generation, Industry, Materials, Process, Recyclate, Recycling, Recycling, Resins, Sustainability, Trending - Tags: Chemical Recycling Heterogeneous thermal catalytic pathways for upcycling polyolefins offer a promising approach towards chemical circularity. Heterogeneous thermal catalytic pathways for upcycling polyolefins offer a promising approach towards chemical circularity. Polyolefin waste, a persistent pollutant, remains a significant challenge for recycling. As an alternative to mechanical recycling, catalytic upcycling can convert polymers into valuable materials. Polyolefins, which account for over 60% of plastic waste, are highly resistant to depolymerization. This is due to their strong C–C bonds and chemical inertness. Additives, fillers, pigments, and mixed polymer streams further complicate recycling in real-world waste streams. Next-generation heterogeneous catalysts, paired with careful engineering considerations, have potential for bridging this gap and supporting a circular plastic economy. You can also read: Upcycling of Polyolefins Through C–H Bond Activation. Metathesis, hydrocracking, and tandem/high-temperature cracking are three primary catalytic methods for polyolefin upcycling. Figure courtesy of Current perspective on heterogeneous thermal catalytic approaches for closed-loop polyolefin plastic recycling. Selectivity and Mild Conditions: Metathesis Metathesis directly converts polyethylene or polypropylene into propylene monomers. This method uses ethylene as a co-reactant and can take place under mild conditions. Metathesis requires substantial amounts of ethylene to drive the reaction. It favors longer-chain olefins, and ethenolysis cleaves the polymer chain’s internal C = C bonds during the reaction. During the reaction, side reactions, such as transfer dehydrogenation, also consume significant ethylene, which is primarily fossil-derived. This reaction produces propylene, which can be polymerized to form polypropylene. Because polypropylene’s market price is about twice that of ethylene, this method, though effective, is not currently commercially appealing. Industrial Maturity and Refinery Compatibility: Hydrocracking Hydrocracking polyolefins to naptha-range... - Published: 2026-09-04 - Modified: 2026-08-31 - URL: https://www.plasticsengineering.org/2026/09/thermoplastic-polyurethane-foams-for-wearable-electronics-012011/ - Categories: 3D Printing/Additive Manufacturing, Editor's Choice Technical Paper, Education & Training, Electrical & Electronics, Foam Processing, Foaming Agents, Industry, Materials, Process, Thermoplastics, Trending Foam Additive Manufacturing tunes TPU foam conductivity for flexible electronics by adjusting temperature and print speed. Foam Additive Manufacturing tunes TPU foam conductivity for flexible electronics by adjusting temperature and print speed. Conductive polymer foams provide a lightweight, low-density material choice for flexible and wearable electronics applications. When printing conductive foams, printing parameters can influence the foam’s electrical and mechanical properties. In a recent study, researchers fabricated conductive TPU foams using FAM. This process leverages CO2 absorption and fused-filament foam (FFF) printing. Through this study, they developed a reproducible framework for controlling the foaming process for optimized conductive performance. Printing paths and parameters impact the properties of conductive foams. Courtesy of Morphology-dependent electrical response of CO2-foamed conductive TPU filaments fabricated by foam additive manufacturing. Conductive Foams: How They Function Conductive foam composites function due to the addition of fillers such as carbon black, Carbon Nanotube (CNT), graphene, or metallic nanoparticles. Increasing filler content can increase conductivity, but can elevate viscosity and lead to agglomeration. Thus, strategies to enhance electrical performance while maintaining processability and mechanical integrity must be employed. You can also read: AM and Conductive Polymers: Next-Gen Aerospace Electronics. Effects of Bubbles and Foam Density Gas bubbles from the polymer foaming process can significantly alter the behavior of conductive polymer composites. Bubbles can change the orientation and interconnection of conductive fillers, promoting interconnectivity and network formation. This can enhance the material’s electrical conductivity and is affected by bubble size. Excessive void fractions can, in turn, disrupt the filler network, decreasing conductivity. Large cells can cause fillers to orient tangentially, limiting interconnectivity. On the contrary, excessively... - Published: 2026-09-03 - Modified: 2026-08-27 - URL: https://www.plasticsengineering.org/2026/09/apricot-shell-flour-enhances-zein-bioplastics-for-packaging-011954/ - Categories: Bioplastics, Circular Economy, Compounding, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, Process, Recycling, Resins, Sustainability, Trending - Tags: Food Packaging, Injection Molding, Sustainable Packaging Apricot shell flour improves ductility, impact strength, and compostability in injection-moldable zein bioplastics for packaging. Apricot shell flour improves ductility, impact strength, and compostability in injection-moldable zein bioplastics for packaging. The plastics industry continues to search for materials that combine sustainability with processability. Protein-based polymers such as zein, derived from corn, offer biodegradability and renewability, but limited ductility and processing constraints have restricted their industrial use. You can also read: Improving Seafood Packaging with Biopolymers and Nanotechnology Turning Agricultural Waste into High-Performance Bioplastics Recent research demonstrates a viable pathway to overcome these limitations by combining zein diethylene glycol (DEG) and apricot shell flour (ASF), a lignocellulosic byproduct. This approach transforms an agricultural residue into a functional component that enhances performance while supporting circular material strategies. The study moves beyond lab-scale film formation and demonstrates that zein can be processed using conventional thermoplastic techniques. Researchers compounded zein with 25 wt% DEG and varying amounts of ASF via extrusion, followed by injection molding at 130°C. This processing route brings protein-based materials closer to industrial reality. It shows that manufacturers can use existing equipment to produce rigid or semi-rigid parts from bio-based formulations without requiring specialized processing technologies. Synergistic Plasticization Drives Exceptional Ductility The most notable outcome lies in the mechanical performance. Zein plasticized with DEG already exhibits high flexibility, reaching a strain at break of 57. 2%. The addition of ASF further enhances this property, increasing strain at break to 119. 2% at the highest filler content. Impact strength shows a similar trend, increasing from 6. 4 to 15. 9 kJ/m2 upon ASF incorporation. These results indicate... - Published: 2026-09-02 - Modified: 2026-08-27 - URL: https://www.plasticsengineering.org/2026/09/petrochemical-feedstock-strategy-shifts-beyond-cost-011929/ - Categories: Business, Circular Economy, Energy Generation, Industry, Materials, People, Polyethylene, Polyolefins, Polypropylene, Recyclate, Resins, Strategy, Sustainability, Trending - Tags: Molecular Recycling Petrochemical feedstock strategy is shifting from lowest cost toward flexibility, carbon reduction, and geopolitical resilience. Petrochemical feedstock strategy is shifting from lowest cost toward flexibility, carbon reduction, and geopolitical resilience. From Refinery Integration to Shale Disruption Europe and much of Asia built petrochemicals on naphtha integrated with refining systems, which optimized co-product value and refinery economics for decades. North America broke that pattern after the shale boom unlocked abundant natural gas liquids, allowing ethane-rich cracking to lower U. S. ethylene costs and shift global cost curves. Analysis by Foster et al. shows how shale gas reshaped supply chains and investment flows. You can also read: Rethinking the System: We Need Molecular Recycling The shift extended beyond cost. Ethane crackers produce fewer co-products than naphtha units, thereby altering propylene and aromatic balances across global markets. Producers adjusted portfolios, and regions became structurally specialized. The New Geography of Advantage The United States now anchors the low-cost end of the global ethylene curve. Data from the U. S. Energy Information Administration shows record ethane production of 2. 8 million barrels per day in 2024. Exports reinforce this advantage, with volumes nearing 500,000 barrels per day and China absorbing nearly half. This flow supports North America’s dominance in polyethylene exports. Surging U. S. ethane production and demand highlight how domestic supply growth underpins both internal consumption and the expansion of export-oriented petrochemical capacity. Courtesy of U. S. Energy Information Administration. Europe faces the opposite dynamic. The European Commission reports that ethylene production costs reached more than triple U. S. levels in 2023. Older, naphtha-heavy assets struggle to compete, and... - Published: 2026-09-01 - Modified: 2026-08-26 - URL: https://www.plasticsengineering.org/2026/09/just-in-time-plastics-processing-faces-new-supply-chain-limits-011924/ - Categories: Business, Composites, Elastomers, Industry, Materials, Medical, Packaging, People, Polyethylene, Polyolefins, Polypropylene, Process, Resins, Results, Silicones, Strategy, Sustainability, Thermoplastics, Thermosets, Trending - Tags: Polymer Additives, PPWR, recycled content, Recycled plastics Just-in-time plastics processing improves efficiency, but additives, recycled content, regulatory requirements, and supply risks now necessitate selective buffering. Just-in-time plastics processing improves efficiency, but additives, recycled content, regulatory requirements, and supply risks now necessitate selective buffering. Just-in-time reshaped plastics processing by attacking inventory at every stage. Processors cut raw-material stocks, reduced work-in-progress, and improved cash flow. Evidence supports those gains. A 2024 meta-analysis in Sustainability found consistent links between JIT adoption and stronger financial performance. You can also read: Building a Resilient Supply Chain in Packaging. Lean Logic Meets Polymer Reality Plastics processors embraced JIT early because their operations rewarded precision. High-volume resins such as polyethylene, polypropylene, and PET flowed predictably through silos and lines. Digital inventory tools and vendor-managed systems reinforced that discipline. According to Yang et al. in the International Journal of Production Economics, JIT performs best when demand signals and supplier coordination remain strong. Under those conditions, processors reduced days of supply without starving production and built systems around silo-level monitoring and automated replenishment. The model worked because materials behaved as expected and suppliers delivered reliably. Where Substitution Breaks Down The limits of JIT appear when plastics stop behaving like commodities. Modern polymer systems depend on additives, stabilizers, and compound formulations. Wiesinger et al. in Environmental Science & Technology show that these inputs create a chemically complex supply base. Material complexity limits substitution and exposes how additives and compliance requirements constrain just-in-time flexibility. Courtesy of Deep Dive into Plastic Monomers, Additives, and Processing Aids That complexity restricts substitution. Processors cannot easily swap materials without requalification. Performance metrics like melt flow, contamination levels, and odour tolerance... - Published: 2026-08-31 - Modified: 2026-08-26 - URL: https://www.plasticsengineering.org/2026/08/how-plastics-supply-chains-became-global-networks-011920/ - Categories: Automotive & Transportation, Business, Composites, Elastomers, Industry, Materials, People, Resins, Sustainability, Thermoplastics, Thermosets, Trending - Tags: Plastics industry, PPWR Plastics supply chains became global through scale, feedstock economics, and shipping, but trade friction is reshaping the model. Plastics supply chains became global through scale, feedstock economics, and shipping, but trade friction is reshaping the model. Mid-20th-century plastics production operated within tightly integrated regional clusters. Producers, converters, and feedstock suppliers are often co-located to minimize transport complexity and cost. That structure limited exposure to logistics risk and reduced reliance on long-distance trade. You can also read: Vietnam – U. S. Plastics Trade: A Strategic Shift in Global Supply Chains Today’s system looks fundamentally different. Plastics supply chains now span multiple borders at each stage, with feedstocks, polymers, intermediates, finished goods, and even waste moving independently across regions. According to UNCTAD, plastics-related trade exceeded $1 trillion in 2018, representing about 5% of global trade. A 2025 trade-linked material flow study estimated that 436. 66 million tonnes of plastics moved globally in 2022. Companies deliberately designed this fragmentation to optimize the system rather than allow it to emerge gradually. Global plastics flows connect feedstocks, production, use, and waste management across borders, illustrating how material moves through an increasingly international and interdependent supply chain. Courtesy of Communications Earth & Environment. Scale and Feedstock Economics Rewired Geography Large-scale petrochemical assets drove the shift toward globalized supply networks. Producers built bigger crackers to reduce unit costs and capture economies of scale. At the same time, feedstock economics created strong regional advantages that reshaped production geography. The International Energy Agency notes that petrochemicals account for 12% of global oil demand. The U. S. shale revolution restored North America as a low-cost producer, with roughly... - Published: 2026-08-28 - Modified: 2026-08-24 - URL: https://www.plasticsengineering.org/2026/08/mclaren-deloitte-and-fia-bring-circularity-to-formula-1-011915/ - Categories: Automotive & Transportation, Business, Circular Economy, Composites, Compounding, Design, Education & Training, Hybrid Manufacturing, Industry, Injection Molding, Materials, Process, Recycling, Regulation, Resins, Sustainability, Thermoforming, Thermoplastics, Thermosets, Trending The F1 Constructors’ Circularity Handbook helps teams measure material use, waste, and circularity in Formula 1 car manufacturing. The F1 Constructors’ Circularity Handbook helps teams measure material use, waste, and circularity in Formula 1 car manufacturing. For decades, Formula 1 has represented the pinnacle of engineering performance, pushing the boundaries of aerodynamics, lightweighting, and advanced materials. Today, however, this sport faces a new challenge: integrating sustainability into one of the world’s most technologically demanding environments without compromising competitiveness. The collaboration between McLaren Racing, Deloitte UK, and FIA shows that sustainability and on-track performance are no longer mutually exclusive. The team has successfully maintained elite speed and safety while reducing its environmental footprint over the last year. A year ago, the organizations developed the F1 Constructors’ Circularity Handbook, a framework designed to measure and improve circularity in the development and manufacturing of Formula 1 cars. With which they assured, “By embracing circular economy practices, teams can minimize their environmental impact and drive innovation in Formula 1”. You can also read: New EU Rules Redefine Automotive Plastics for Sustainability in 2025. Measuring Circularity in High-Performance Manufacturing The F1 Constructors’ Circularity Handbook introduces a standardized methodology that enables teams to evaluate their material use, waste management, and the integration of circular practices into chassis manufacturing. Rather than relying on isolated sustainability initiatives, the framework establishes a measurable system to track circularity throughout the entire lifecycle of Formula 1 components. The handbook includes: A step-by-step methodology to identify and gather data, as well as estimate data to fill any gaps. Definitions of how to apply circularity criteria to differentiate input materials and... - Published: 2026-08-27 - Modified: 2026-08-24 - URL: https://www.plasticsengineering.org/2026/08/sustainable-tire-materials-support-pirellis-esg-performance-011911/ - Categories: Automotive & Transportation, Business, Circular Economy, Elastomers, Industry, Materials, People, Process, Recycling, Results, Strategy, Sustainability, Thermoplastics, Trending - Tags: Polymers Pirelli enters the Top 1% of S&P Global’s 2026 Sustainability Yearbook, driven by ESG performance and sustainable tire innovation. Pirelli enters the Top 1% of S&P Global’s 2026 Sustainability Yearbook, driven by ESG performance and sustainable tire innovation. With the increasing pressure to reduce GHG emissions from vehicles, auto parts suppliers play a critical role in innovating low-carbon solutions. A circular economy approach plays a vital role because raw materials account for a large share of production costs. Companies now need to prioritize performing lifecycle assessments to select the most sustainable inputs. Sustainability Metrics Meet Operational Risk Ongoing disruptions in supply chains and energy markets expose the industry to broader operational risks. At the same time, the rising use of conflict minerals and rare earth elements in alternative drivetrains pushes manufacturers to secure responsible suppliers and improve transparency. In the automotive sector, passenger safety remains essential, requiring auto parts suppliers to identify and address potential hazards early. Meanwhile, autonomous driving technologies create new business opportunities for component manufacturers while raising the bar for quality standards. Pirelli understood these rising necessities and therefore scored eighty-six points in the Corporate Sustainability Assessment (CSA). Positioning the company at the highest level both in the Auto Components sector and making it the only tire manufacturer worldwide to have achieved this recognition. You can also read: Tire Recycling: Feasibility and Profitability From Sustainable Inputs to ESG Leadership Material innovation alone does not define sustainability leadership. It must align with broader corporate strategy, measurable outcomes, and transparent reporting. This is why S&P Global breaks down its criteria with the respective weight in the following way:... - Published: 2026-08-26 - Modified: 2026-08-24 - URL: https://www.plasticsengineering.org/2026/08/transporting-plastics-in-a-low-carbon-economy-011894/ - Categories: Automotive & Transportation, Bioplastics, Business, Circular Economy, Composites, Editor's Choice Technical Paper, Elastomers, Industry, Materials, People, Polyolefins, Process, Regulation, Resins, Results, Strategy, Sustainability, Thermoplastics, Thermosets - Tags: Carbon Footprint Low-carbon transport strategies can reduce emissions across plastics supply chains, from resin logistics to the movement of recycled materials. Low-carbon transport strategies can reduce emissions across plastics supply chains, from resin logistics to the movement of recycled materials. Logistics Moves into the Scope 3 Spotlight Polymer producers once focused decarbonization efforts inside plant boundaries. That focus now extends across logistics networks and transport decisions. Companies must now account for emissions from shipping, trucking, and distribution under Scope 3 frameworks. You can also read: How Blockchain is Transforming Plastic Waste Management. Transport choices increasingly influence procurement decisions and product carbon footprints. According to ISO 14083 guidance, companies must quantify emissions across entire freight chains using standardized methods. This requirement raises scrutiny on how resin and feedstock move globally. Major producers already respond. Dow’s 2024 reporting highlights deeper collaboration with logistics providers and suppliers on emissions tracking and reduction. These efforts reflect a broader shift. Logistics now functions as a strategic lever rather than a transactional cost. The shift toward low-carbon energy systems is reshaping industrial logistics, pushing plastics transport toward cleaner fuels, stricter accounting, and new cost structures. Courtesy of Dow. Regulation Rewrites Freight Economics European policy now reshapes the economics of polymer transport. The EU Emissions Trading System covers maritime shipping, with full emissions obligations approaching by 2027. This framework directly increases costs for carbon-intensive shipping routes into Europe. FuelEU Maritime adds further pressure by mandating reductions in the greenhouse gas intensity of marine fuels from 2025 onward. Together, these measures alter carrier selection and route planning for global resin trade. Road freight faces similar regulatory tightening. Revised EU... - Published: 2026-08-25 - Modified: 2026-08-24 - URL: https://www.plasticsengineering.org/2026/08/carbon-black-pigments-create-new-recycling-compliance-challenges-011883/ - Categories: Additives & Colorants, Automotive & Transportation, Circular Economy, Compounding, Design, Durables, Editor's Choice Technical Paper, Extrusion, Industry, Industry 4.0, Injection Molding, Materials, Mixing & Blending, Packaging, Process, Recycling, Sports & Recreation, Sustainability, Trending - Tags: circular packaging, Design for Recycling, Extended producer responsibility, plastic additives, plastic recycling, PPWR Carbon black pigments limit NIR sorting, raising recyclability, compliance, and cost challenges for black plastic packaging. Carbon black pigments limit NIR sorting, raising recyclability, compliance, and cost challenges for black plastic packaging. Carbon black remains the dominant pigment in plastic packaging. It delivers opacity, UV resistance, and cost efficiency. However, it creates a critical limitation in plastics recycling systems. Material recovery facilities depend on near-infrared sorting to identify polymers. Black packaging appears across food, personal care, and household applications. Each undetected unit lowers overall system efficiency. This issue no longer sits at the material level. It now affects system-wide recycling performance and recovery targets. You can also read: New BASF Black Pigment for Cars Carbon black absorbs infrared radiation, preventing polymer detection. Sorting systems fail to identify black plastics and remove them from recycling streams. Data from Resources, Conservation & Recycling confirms that NIR systems cannot reliably detect carbon-black-filled polyolefins. This limitation reduces sorting yield and increases landfill rates. It affects packaging that recyclers could otherwise process. Regulatory Frameworks Redefine Material Acceptability Regulators and industry bodies now treat detectability as a design requirement. RecyClass classifies carbon-black packaging as non-recyclable under current. The APR Design Guide discourages its use in rigid packaging streams. These frameworks influence design specifications across global FMCG supply chains. The EU Packaging and Packaging Waste Regulation links recyclability performance to extended producer responsibility fees. Non-detectable packaging increases compliance costs and financial exposure. Pigment selection now influences the total cost of ownership. Carbon black creates downstream cost penalties despite a low upfront cost. Engineering teams must align formulation decisions with regulatory and system constraints.... - Published: 2026-08-24 - Modified: 2026-08-18 - URL: https://www.plasticsengineering.org/2026/08/scaling-plastics-recycling-without-overcommitting-capital-011878/ - Categories: Business, Industry, Legal Analysis, People, Process, Results, Strategy, Trending - Tags: Advanced Recycling, Chemical Recycling, Mechanical Recycling, PPWR, pyrolysis CapEx strategy now shapes the scale of plastics recycling, balancing flexibility, feedstock control, compliance, and long-term margins. CapEx strategy now shapes the scale of plastics recycling, balancing flexibility, feedstock control, compliance, and long-term margins. Flexibility Accelerates Early Adoption Plastic circularity has moved from pilot projects to industrial deployment. Companies now face a critical allocation decision under growing regulatory pressure. How they deploy capital, not whether they deploy it, defines their competitive position. Capital expenditures (CapEx) light strategies dominate early adoption. Firms rely on partnerships, tolling agreements, and external recyclers instead of building infrastructure. This approach minimizes upfront investment and accelerates market entry. Research in Progress in Polymer Science finds that mechanical recycling systems favor distributed models. Contamination constraints and feedstock variability make lower-capital, flexible operations the natural fit. Companies benefit from optionality. They can shift suppliers, evaluate technologies, and respond quickly to regulatory changes. This flexibility proves essential as advanced recycling technologies continue to evolve. However, reliance on third parties introduces structural risk. Limited availability of high-quality waste streams restricts supply. As demand for secondary polymers rises, access becomes a competitive constraint rather than price alone. Ownership Secures Scale and Margins CapEx-heavy strategies emerge as companies seek control and scale. Large players invest directly in recycling plants, sorting infrastructure, and feedstock processing systems. Chemical recycling illustrates this transition clearly. A 2023 review in Renewable and Sustainable Energy Reviews confirms that pyrolysis and depolymerization require significant capital. Reaching commercial scale demands that investment go upfront. Companies pursue vertical integration to secure feedstock and stabilize margins. Petrochemical producers and waste management firms increasingly form joint ventures to control supply... - Published: 2026-08-21 - Modified: 2026-08-18 - URL: https://www.plasticsengineering.org/2026/08/what-makes-a-bio-based-coating-commercially-viable-011873/ - Categories: Bioplastics, Business, Cast Film/Sheet, Circular Economy, Decorating & Coatings, Design, Education & Training, Film, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, Process, Recycling, Resins, Semi-Finished Products, Sustainability, Trending Bio-based coatings use plant oils, lignin, cellulose, and starch to improve sustainability, durability, adhesion, and industrial performance. Bio-based coatings use plant oils, lignin, cellulose, and starch to improve sustainability, durability, adhesion, and industrial performance. The coatings industry has reduced volatile organic compounds, improved curing technologies, and expanded the use of waterborne formulations over the past several decades. Yet most commercial coating systems still depend heavily on petroleum-derived raw materials. You can also read: Renewable Functional Coatings for Advanced Applications As manufacturers seek renewable alternatives, bio-based coatings have emerged as a promising area of development. The challenge is no longer identifying renewable feedstocks. The challenge is converting those feedstocks into coating materials that meet the durability, adhesion, and processing requirements of industrial applications. Recent research suggests that advances in chemical modification and biomass conversion are helping close that performance gap. Expanding Feedstock Options Bio-based coatings derive their components from renewable biomass sources. Plant oils remain among the most widely used feedstocks due to their availability and chemical versatility. Soybean, linseed, castor, and canola oils have all been investigated for coating applications. Other promising materials include lignin, cellulose, starch, rosin, and chitosan. Researchers are also exploring polymers produced through microbial fermentation. Representative feedstock sources of sustainable biopolymers, categorized by origin (plants, marine algae, animals, fungi, bacteria). Courtesy of Extraction, Characterization and Applications of Biopolymers from Sustainable Sources. Each feedstock offers distinct advantages. Plant oils provide reactive molecular structures suitable for resin synthesis. Lignin contributes natural UV absorption and barrier properties. Cellulose delivers mechanical reinforcement and abrasion resistance. Starch offers film-forming capability and biodegradability. These characteristics allow bio-based materials to... - Published: 2026-08-20 - Modified: 2026-08-13 - URL: https://www.plasticsengineering.org/2026/08/xenia-hm-upgrade-boosts-carbon-fiber-composite-stiffness-011906/ - Categories: Automotive & Transportation, Business, Circular Economy, Composites, Compounding, Design, Education & Training, Industry, Injection Molding, Materials, Mixing & Blending, Process, Recycling, Resins, Sustainability, Thermoforming, Thermosets, Trending - Tags: Dimensional Stability Xenia’s HM Upgrade improves carbon fiber-reinforced thermoplastics with higher stiffness, strength, impact resistance, and dimensional stability. Xenia’s HM Upgrade improves carbon fiber-reinforced thermoplastics with higher stiffness, strength, impact resistance, and dimensional stability. Nowadays, industries increasingly demand lighter, stiffer, and more durable materials for high-performance ends. This is why carbon fiber–reinforced thermoplastics have become the cornerstone of modern engineering. Nevertheless, as performance approaches the maximum thresholds, the material's basis is no longer sufficient. With the introduction of its HM (High Modulus) Upgrade technology, Xenia Materials is addressing this challenge. Researchers redefine carbon fiber at its core to demonstrate how engineers manipulate stiffness and structural response within thermoplastic composites. You can also read: Confronting the Challenges of Carbon Fiber Recycling Engineering Stiffness at the Fiber Level At the core of the HM Upgrade lies a straightforward but impactful concept: replacing standard carbon fibers with high-modulus variants to enhance stiffness without increasing weight. The result is a new application across the carbon fiber-reinforced material XECARB portfolio that delivers a measurable boost in mechanical performance. According to Xenia, this technology can increase tensile modulus by approximately 15% compared to conventional formulations, while maintaining the same density By offering superior precision and dimensional stability, this technology unlocks an innovative design potential for components that must maintain mechanical integrity under demanding load conditions. Xenia also notes that this technology can increase impact resistance by 20% and tensile strength and flexural modulus by 15%, while preserving its lightweight nature. Engineers assessed the impact strength under demanding operating conditions and demonstrated consistently improved mechanical behavior at both -30°C and +23°C. This balance is critical.... - Published: 2026-08-19 - Modified: 2026-08-13 - URL: https://www.plasticsengineering.org/2026/08/why-emotional-packaging-matters-to-younger-consumers-011899/ - Categories: Business, Design, Flexible Packaging, Food Packaging, Industry, Materials, Packaging, People, Strategy, Sustainability, Trending Packaging design is shifting toward tactile, emotional, and transparent experiences that build trust with younger consumers. Packaging design is shifting toward tactile, emotional, and transparent experiences that build trust with younger consumers. The consumers now entering their peak purchasing years carry expectations that challenge packaging at its most fundamental level: what a container communicates, how it feels in the hand, and what story it tells before the product inside is ever tasted. For packaging designers, understanding these expectations is becoming as important as understanding shelf dynamics. You can also read: Neo Vintage Design: How Generation Z is Rewriting the Rules of Nostalgic Packaging. When Packaging Becomes Emotional Territory DIVERSA's tequila label weaves five independent design voices from across Latin America into a single surface, each agency contributing a quadrant that interlocks like threads in a traditional textile, proving that collaborative authorship can produce a visual density no single studio would have reached alone. Concept and creative direction by Tridimage. Younger consumers increasingly seek emotional resonance in the products they buy. Comfort, nostalgia, and sensory pleasure drive purchase decisions alongside nutrition and price. Packaging responds. Surface textures that evoke warmth, color palettes calibrated to trigger specific moods, typographic choices that whisper familiarity. The shelf is becoming a landscape of emotional cues, where the most successful designs are those that make consumers feel something before they read a single word. Transparency You Can See Through Vertigreens' greenhouse-shaped container transforms the brand's indoor farming technology into an architectural statement on the shelf. The clear structure turns material transparency into a literal trust signal where nothing is hidden between consumer... - Published: 2026-08-18 - Modified: 2026-08-05 - URL: https://www.plasticsengineering.org/2026/08/microplastics-raise-concerns-over-antimicrobial-resistance-011869/ - Categories: Circular Economy, Education & Training, Elastomers, Industry, Materials, Medical, Microplastics, Packaging, People, Process, Resins, Sustainability, Thermoplastics, Thermosets - Tags: microplastic pollution Microplastics can host microbial biofilms containing pathogens and antimicrobial resistance genes in aquatic environments. Microplastics can host microbial biofilms containing pathogens and antimicrobial resistance genes in aquatic environments. Microplastics have become one of the most widely distributed forms of pollution on the planet. Researchers have detected them in oceans, rivers, lakes, soils, wastewater systems, and even the human body. Scientists estimate that as many as 125 trillion microplastic particles now exist on the surface of the world's oceans. For years, research focused largely on the physical impacts of these particles. Studies examined their persistence, movement through ecosystems, and effects on wildlife. More recently, however, researchers have begun investigating another characteristic of microplastics. Once they enter the environment, they are no longer inert particles. Instead, they become habitats for microbial communities. You can also read: When Microplastics Meet PFAS: A Toxic Partnership in the Environment From Plastic Particles to Biological Surfaces These communities form biofilms on the particle surface. Collectively, they are known as the "plastisphere. " Researchers have found that the plastisphere can contain bacteria, pathogens, and antimicrobial resistance (AMR) genes. This has raised important questions about the role of microplastics in transporting microorganisms through aquatic environments. A recent study published in Environment International explored this issue by tracking microbial colonization across a wastewater-to-marine pathway. The research examined how microorganisms colonize different materials under real environmental conditions and whether plastic substrates behave differently from natural or inert surfaces. To conduct the study, researchers deployed materials at four locations representing decreasing levels of pollution. The sites included hospital wastewater, an upstream river location, a downstream... - Published: 2026-08-17 - Modified: 2026-08-05 - URL: https://www.plasticsengineering.org/2026/08/how-product-design-shapes-medical-plastics-recovery-011787/ - Categories: Bioplastics, Business, Circular Economy, Design, Industry, Materials, Medical, People, Process, Recyclate, Recycling, Recycling, Resins, Silicones, Sustainability, Thermoplastics, Trending - Tags: Chemical Recycling, Healthcare Plastics, Mechanical Recycling, Medical Plastics Medical plastics recovery depends on product architecture, contamination control, resin choice, and end-of-life design strategy. Medical plastics recovery depends on product architecture, contamination control, resin choice, and end-of-life design strategy. Medical plastics cannot follow the same recovery logic as consumer packaging. A consumer container needs compatible resin chemistry, access to sorting, and downstream market value. Medical products face a narrower design window because they must meet sterility, biocompatibility, traceability, cleaning, and performance requirements. They may also come into contact with body fluids, drugs, disinfectants, or sterilization processes, which can change polymer behavior and recovery options. As a result, recovery depends on product architecture, not only on post-use waste handling. For that reason, the recovery route should enter the specification stage early. Designers need to decide whether the product can support reuse, regulated reprocessing, mechanical recycling, chemical recycling, or disposal. Each route requires a different polymer architecture, additive package, and joining strategy. You can also read: Sustainable Healthcare Plastics: Rethinking Design, Use, and Recovery Reuse: Durable Plastics Reuse fits durable medical components, not most disposable patient-contact items. Typical examples include sterilization trays, instrument handles, rigid housings, diagnostic equipment covers, and some fluid-management accessories. These parts need polymers that tolerate repeated cleaning and sterilization without distortion, cracking, discoloration, or surface damage. For that reason, material selection sets the first limit. PPSU, PSU, PEEK, PEI, and selected high-temperature polycarbonates can handle higher thermal and chemical stress than commodity resins. PPSU can suit reusable trays or handles exposed to repeated steam sterilization, while PEEK can support components that need stiffness, hydrolysis resistance, and dimensional stability. These materials support reuse... - Published: 2026-08-14 - Modified: 2026-08-05 - URL: https://www.plasticsengineering.org/2026/08/capturing-co2-with-upcycled-gloves-011847/ - Categories: Circular Economy, Elastomers, Industry, Materials, Medical, People, Process, Recycling, Recycling, Silicones, Sustainability, Thermoplastics, Trending - Tags: Circular Economy, sustainable materials Upcycled nitrile and SBS rubbers can become solid polyamine sorbents for CO₂ capture and rubber waste recovery. Upcycled nitrile and SBS rubbers can become solid polyamine sorbents for CO₂ capture and rubber waste recovery. Recent estimates from the United Nations Environment Programme indicate that annual global plastic production exceeds 400 million metric tons. As plastic waste accumulates, it could generate massive CO₂ emissions and require significant removal capacity by 2050. Some estimates indicate that the world may need to remove 5–16 gigatons of CO₂ by then. Therefore, carbon storage technologies such as direct air capture and carbon capture will become increasingly important. Current industrial systems usually rely on aqueous amine solutions or metal-organic frameworks (MOFs). Although these methods can be highly efficient, they still face key technical limitations. These challenges include sorbent evaporation, structural instability, and high energy demand during regeneration. You can also read: Bio-Based Synthetic Rubbers: A Sustainable Shift in Plastics. Carbon Capture with Waste Upcycling Next-generation solid adsorbents may help reduce many of these drawbacks. These materials include amine-grafted or amine-impregnated supported systems. To address these challenges, Danish chemists developed a new approach to upcycle nitrile and styrene-butadiene-styrene rubbers. This work introduces a promising circular route for processing these difficult rubber waste streams. Building on advances in next-generation sorbents, Professor Troels Skrydstrup and his team at Aarhus University linked carbon capture with waste upcycling. They developed a method to repurpose used and discarded nitrile rubber, including single-use laboratory gloves, into functional solid sorbents. In their recent paper, Post-Modified Nitrile and Styrene-Butadiene-Styrene Rubbers, the team outlines two synthetic routes. These routes convert nitrile and SBS... - Published: 2026-08-13 - Modified: 2026-08-05 - URL: https://www.plasticsengineering.org/2026/08/digital-twins-and-predictive-analytics-in-plastics-supply-chains-011555/ - Categories: Artificial Intelligence, Business, Design, Education & Training, Industry, People, Regulation, Results, Software, Strategy, Sustainability, Trending Plastics supply chains are moving from fragmented visibility to predictive control through digital twins, AI, and traceability tools. Plastics supply chains are moving from fragmented visibility to predictive control through digital twins, AI, and traceability tools. Plastics supply chains still struggle with fragmented data across production, planning, and distribution systems. Legacy ERP platforms and siloed plant data limit end-to-end visibility across multi-tier feedstock networks. From Fragmented Visibility to Predictive Control The industry now moves beyond visibility toward predictive capability. Companies deploy AI-driven demand sensing, ETA prediction, and disruption modeling to manage volatile resin markets. Analysis by Artificial Intelligence in Supply Chain Management shows that machine learning improves forecast accuracy and responsiveness. This shift matters because plastics supply chains operate under unique constraints. Grade-level variability and tight processing windows increase uncertainty costs, especially in the form of delays and excess inventory. Predictive tools reduce uncertainty and improve coordination across production and delivery. These tools enable more efficient operations and reduce costs in plastics supply chains. You can also read: Building a Resilient Supply Chain in Packaging Digital Twins Reshape Operational Decision-Making Digital twins deliver measurable gains across the value chain. BCG data points to 20–30% improvements in forecast accuracy and 85% reductions in overall cycle planning times for early adopters. Courtesy of BCG. Digital supply chain twins have become an important innovation that brings together plant data, supply chain flows, and customer demand into a single simulation space Research from Digital Supply Chain Twin shows how real-time models can mimic disruptions and change flows in real time. Polymer producers increasingly evaluate these capabilities to manage feedstock swings and supply... - Published: 2026-08-12 - Modified: 2026-08-05 - URL: https://www.plasticsengineering.org/2026/08/uk-pfas-plan-sets-national-monitoring-framework-011865/ - Categories: Education & Training, Industry, Materials, People, PFAS, Regulation, Sustainability, Trending - Tags: Fluoropolymers, Waste Management The UK PFAS Plan expands monitoring, reporting, and regulatory oversight of forever chemicals in water, waste, and industry. The UK PFAS Plan expands monitoring, reporting, and regulatory oversight of forever chemicals in water, waste, and industry. The UK government published its first national plan on per- and polyfluoroalkyl substances (PFAS) in 2026. The plan establishes a coordinated framework for monitoring, exposure assessment, and future regulatory controls. It responds to growing evidence of PFAS persistence across the UK. You can also read: PFAS Contamination Tests the Limits of UK Policy PFAS have been detected in surface water, groundwater, and soils across the country. Monitoring programs have also identified PFAS in drinking water sources. As a result, the UK is strengthening detection and reporting measures. These efforts align with broader international initiatives. The challenge extends well beyond the UK. The Organisation for Economic Co-operation and Development has identified more than 4,700 PFAS substances. Manufacturers use many of these substances in polymer processing, coatings, and surface treatments. Expanded Monitoring and Data Collection A central element of the UK PFAS Plan is the expansion of environmental monitoring. The framework commits to increasing data collection across water systems, waste streams, and industrial emissions. The plan highlights the need for improved analytical capability. Current detection methods, including targeted chemical analysis and total organic fluorine screening, are being expanded to capture a broader range of PFAS compounds. This reflects the complexity of PFAS chemistry, where substances often appear as mixtures or transformation products. The UK also plans to strengthen reporting mechanisms. This includes collaboration between the Environment Agency and water regulators to track PFAS concentrations... - Published: 2026-08-11 - Modified: 2026-08-05 - URL: https://www.plasticsengineering.org/2026/08/pa6f-nanofiber-membranes-offer-sustainable-pfas-removal-011858/ - Categories: Composites, Editor's Choice Technical Paper, Education & Training, Hybrid Manufacturing, Industry, Materials, People, PFAS, Polyamide, Process, Sustainability, Trending Bio-based PA6F nanofiber membranes capture PFAS from water and support reuse through thermal regeneration and reprocessing. Bio-based PA6F nanofiber membranes capture PFAS from water and support reuse through thermal regeneration and reprocessing. Per- and polyfluoroalkyl substances (PFAS) remain one of the most persistent contaminants in water systems. Their strong carbon–fluorine bonds prevent natural degradation, allowing them to accumulate in the environment over time. These “forever chemicals” are widely used in industries such as textiles, coatings, and microelectronics, making their presence difficult to control. PFAS: A Persistent Industry Challenge Growing evidence links PFAS exposure to serious health risks, including cancer and immune system disruption. This has increased regulatory pressure on industries and water utilities. However, current treatment methods remain limited. Conventional adsorbents such as activated carbon and ion-exchange resins often require frequent replacement and generate secondary waste. More advanced approaches, while effective, tend to be energy-intensive and difficult to scale. You can also read: When Microplastics Meet PFAS: A Toxic Partnership in the Environment A Research Breakthrough from the University of Bath Researchers at the University of Bath have developed a bio-based polymer membrane that offers a different approach. The material is designed not only to capture PFAS efficiently but also to support reuse and circular processing. The membrane is based on a semi-aromatic polyamide, poly(hexamethylene 2,5-furandicarboxylamide) or PA6F, derived from renewable furan-based feedstocks. This structure combines the mechanical robustness of conventional nylons with enhanced polarity and interaction capability. According to the research team, the material behaves differently from traditional petroleum-based polyamides. Its structure actively responds to water, enabling improved pollutant capture and retention. Water-Activated Capture Mechanism... - Published: 2026-08-10 - Modified: 2026-08-03 - URL: https://www.plasticsengineering.org/2026/08/btx-aromatics-drive-high-performance-resins-and-polymers-011855/ - Categories: Aerospace, Automotive & Transportation, Business, Editor's Choice Technical Paper, Education & Training, Elastomers, Energy Generation, Industry, Materials, Polycarbonate, Polyolefins, Polyurethane, Process, Recycling, Regulation, Resins, Sustainability, Testing & Analysis, Thermoplastics, Thermosets, Trending - Tags: Dimensional Stability, Nylon, PET, Thermal Stability BTX aromatics provide key building blocks for resins, polyesters, polyamides, and high-performance plastics. BTX aromatics provide key building blocks for resins, polyesters, polyamides, and high-performance plastics. The BTX aromatics, benzene, toluene, and xylenes, are basic hydrocarbons characterized by their six-carbon ring structure. This structure gives them distinctive chemical stability. That is why BTX compounds serve as the starting platform for many engineering polymers. It is the benzene ring that provides rigidity, thermal stability, and resistance to oxidation; qualities that aliphatic chains cannot match. In industrial practice, it is not only volume that matters but also the ability to pursue selective pathways toward high-margin monomers. You can also read: Inside Materials – Kevlar. Introduction to BTX Production Crude oil provides almost all aromatics; however, coal produces small quantities. The most important industrial route for BTX production is the catalytic reforming of naphtha, also known as the platforming process. This accounts for 70% of the global supply of BTX. Some modern facilities use technologies such as CCR platforming to create aromatic rings from paraffins and naphthenes. Refineries achieve this through dehydrogenation, dehydrocyclization, and isomerization processes using bifunctional catalysts. This route dominates because it combines high conversion with hydrogen recovery. Other emerging methods include the Cyclar process, which directly converts LPG into high-purity liquid aromatics. There are also methods that use gallium-aluminum-silicate catalysts to aromatize light alkanes such as propane. More specifically, Parex-type adsorption systems allow for the recovery of p-xylene with higher yield and purity than crystallization. Other secondary methods utilize byproducts from ethylene plants, such as pyrolysis gasoline (pygas). To a lesser extent, producers... - 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 additives, 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: Automotive plastics, 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 - Tags: Automotive plastics, Polymer Additives 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: Healthcare Plastics, 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 - Tags: Polymer Additives 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... ## 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. 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