Fraunhofer IAP at Fakuma 2026 Material Developments for Recyclable Plastics

At Fakuma 2026, the Fraunhofer IAP will present materials science solutions for a circular plastics industry. The range extends from chemically modified PLA and new material cycles for PET to self-reinforcing monomaterials and bio-based carbon fibers.

The Fraunhofer Institute for Applied Polymer Research (IAP) will present developments in recyclable plastics and chemical recycling at Fakuma 2026. For the first time, the institute will be exhibiting at the Tecpart joint booth as a new member of the Association for Technical Plastic Products (Tecpart).

Plastics processors face the challenge of tapping into alternative sources of raw materials and implementing circular economy concepts without compromising mechanical properties or cost-effectiveness. To address fluctuating recycled material qualities and varying flow properties, researchers at Fraunhofer IAP are specifically tailoring the material structure, formulation, and process parameters to the respective processing equipment. 

Flexible PLA Films

A chemical modification of the polymer chain makes brittle polylactide (PLA) suitable for the production of flexible and recyclable films. Unlike conventional compounding processes, this targeted intervention in the macromolecules fundamentally alters the material’s thermal and rheological behavior. The modified biopolymer can be processed on established extrusion lines in the same way as low-density polyethylene (LDPE). This eliminates the need for costly investments in new machinery or tooling modifications for film manufacturers.

In addition, the institute is presenting the self-reinforced monomaterial sc-PLA, in which the matrix and reinforcing fibers are made of the same polymer, thereby eliminating the need for labor-intensive material separation during mechanical recycling. 

PUR film is turned into foam

Programmed shape changes expand the range of applications for functional polymers through targeted temperature pulses. The FOIM demonstrator exhibit illustrates this reactive mechanism: Upon thermal activation at 60 °C, a 2.5 mm-thick polyurethane film expands into a 40 mm-high foam, corresponding to a 16-fold increase in volume. Another exhibit is a shrinkable door opener manufactured using 4D printing, which combines thermal shape changes with additive manufacturing processes.

New Recycling Loops for PET

In addition to mechanical separation methods, the chemical recycling of PET waste and used textiles as a source of raw materials is gaining importance. Through the depolymerization of polyethylene terephthalate, researchers recover pure terephthalic acid, which they then use to synthesize new polymers with defined mechanical properties. Developers use targeted additives to control the yellowish to grayish hues found in recycled materials, even achieving complete colorlessness. The institute also produces the bio-based plastic polyhydroxybutyrate (PHB) from PET-containing textile waste for new material cycles. 

For industrial material substitution, the developers tested new types of polybutylene succinate (PBS) on a pilot scale. The PBS variants developed are suitable for common manufacturing processes such as injection molding, blow molding, thermoforming, extrusion, and fiber spinning.

At the same time, bio-based carbon fibers are being produced from cellulose and lignin for lightweight construction applications, batteries, and fuel cells. Through thermal process control and fiber structure, mechanical strength, porosity, and electrical conductivity can be precisely tailored to meet specific requirements. 

Through its membership in TecPart, the institute contributes its expertise to discussions with manufacturers of technical plastic products and demonstrates how materials development and industrial processing can be integrated.