Imagine replacing heavy, oil-based plastics with lightweight, plant-based foams that are just as strong. It's like switching from a heavy plastic brick to a sturdy, eco-friendly sponge that can be 3D printed or molded. This makes products lighter and easier to recycle when they are no longer needed.
Bio-based plastics are often hard to process, lack durability, and are difficult to recycle, preventing them from replacing fossil-based plastics in high-volume manufacturing.
Three processing value chains: granulated feedstock 3D printing, radio-frequency bead foaming, and AI-controlled Foam Injection Moulding, along with a material property database.
If you are a car interior component manufacturer dealing with high carbon footprints and heavy parts — this project developed bio-based foamed thermoplastics that reduce weight and can mitigate ~75,000 tonnes CO2 eq/year.
If you are a ship interior designer dealing with strict flame retardancy and weight requirements — this project developed high-strength, flame-retardant bio-based blends and 3D printing processes to reduce lead times and costs.
If you are a white goods manufacturer dealing with plastic waste and rigid production cycles — this project developed Foam Injection Moulding with AI-based control to ensure part conformity and high recyclability.
The project addresses cost challenges by optimizing processing techniques and material use to make bio-based alternatives more economically viable.
Yes, the project utilizes a Learning Factory providing access to pilot scale industrial lines for three different value chains to reduce adoption risk.
Based on available project data, the project creates an open database of bio-based material properties to speed up industry adoption.
The project uses AI-based process control in Foam Injection Moulding to tightly manage temperature, speed, and residence times for part conformity.
The project runs from 2022-06-01 to 2025-11-30, meaning the developed processes and materials are reaching maturity by late 2025.
The consortium is heavily industry-driven with a 67% industry ratio, comprising 10 industrial partners and 3 SMEs across 7 countries. This strong commercial presence, balanced by 5 research organizations, indicates a high focus on market application rather than pure theory.
Contact TEKNOLOGIAN TUTKIMUSKESKUS VTT OY in Finland
Contact us to access the bio-based material property database.
