Fraunhofer IAP: Recyclable polymers and bio-based carbon fibres

The Fraunhofer Institute for Applied Polymer Research IAP is presenting developments in plastics designed for recycling, chemical recycling, functional polymers and bio-based carbon fibres at Fakuma 2026. As a new member of TecPart – the German association for technical plastic products – the institute is participating in the association’s joint exhibition for the first time. The focus is on aligning polymer structure, material properties and processing to enable the use of alternative raw materials in industrial applications.

The exhibits include a flexible, recyclable film based on polylactide (PLA). The originally rigid polymer was chemically modified to broaden its property profile for flexible film applications. According to the institute, the material can be processed on standard equipment in a similar way to low-density polyethylene (LDPE). The development is based on modifying the polymer rather than producing a conventional compound.

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The self-reinforced mono-material "sc-PLA" combines a PLA matrix with reinforcing fibres made from the same polymer. This is intended to eliminate complex separation steps between different material components during recycling. The approach takes recyclability into account from the material development stage.

In the field of chemical recycling, Fraunhofer IAP is demonstrating the recovery of terephthalic acid from polyethylene terephthalate (PET). The institute uses the recovered monomer to produce polymers again and examines their mechanical properties and colour. PET is used in products including bottles, fibres and films. Another approach uses PET-containing waste textiles as feedstock for producing polyhydroxybutyrate (PHB). The institute is thereby investigating the use of a textile waste stream that is difficult to recycle as a raw material for new polymers.

Together with industrial partners, Fraunhofer IAP has also developed new grades of polybutylene succinate (PBS), which have been produced and processed on a pilot scale. The grades are designed for different processes, including injection moulding, blow moulding, thermoforming, extrusion and spinning. The institute identifies packaging, consumer goods and textiles as potential applications.

Functional polymers are presented through temperature-activated shape changes. In the "Foim" demonstrator, a 2.5-millimetre-thick polyurethane film becomes a foam measuring 40 millimetres in height at 60 degrees Celsius. This corresponds to a sixteenfold expansion in height. A shrink-fit door opener produced using 4D printing demonstrates the combination of shape-memory properties and additive manufacturing. According to the institute, mechanical recycling remains possible.

For lightweight construction and energy applications, Fraunhofer IAP is developing carbon fibres from renewable raw materials such as cellulose and lignin. Mechanical properties, porosity, geometry and electrical conductivity, among other characteristics, are tailored through the choice of feedstock, fibre structure and process conditions. Depending on the property profile, potential applications include lightweight construction, batteries and fuel cells.

Fakuma 2026
Friedrichshafen, Germany
12–16 October 2026
Hall A5, Stand 5104

More information: www.iap.fraunhofer.de

Fraunhofer-Institut für Angewandte Polymerforschung IAP, Potsdam-Golm, Germany

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