Periodic Reporting for period 2 - VITAL (InnoVatIve processing Technologies for bio-based foAmed thermopLastics)
Reporting period: 2023-12-01 to 2025-11-30
Biobased thermoplastics (bbTP) are well established in packaging, yet their uptake in durable and long life applications remains limited. Key barriers include restricted large scale availability, comparatively high costs, processing challenges and performance limitations. Despite these constraints, bbTPs offer clear potential to reduce the environmental footprint of products and manufacturing processes. Expected near term increases in global production capacity are likely to alleviate supply and cost pressures. Within this context, the VITAL project set out to address the remaining obstacles related to material performance and processing. The project focused on the development of lightweight thermoplastic products, exploiting foaming technologies to reduce raw material use. Compared to conventional thermoset foams, thermoplastic foams offer substantial advantages for recyclability and circularity.
VITAL contributes towards EU initiatives particularly in economic, green and manufacturing growth.
VITAL contributes towards EU initiatives particularly in economic, green and manufacturing growth.
VITAL project delivered major advances in three bbTP processing value chains, creating new manufacturing capabilities, materials and digital tools that improve sustainability and industrial adoption.
1. VITAL developed a novel 3D foam printing head capable of processing granulates with direct gas injection, eliminating the need for filament production and enabling density control during printing. The technology supports a wide range of plastics and achieved up to 66% weight reduction through foaming. Its functionality was demonstrated by producing a large-scale, recyclable PLA separation wall for cruise ships, showing improved mechanical and thermal performance over traditional PLA and offering a more sustainable alternative to glass-fibre composites.
2. Project created a steam free, radio frequency-based bead foaming process, ideal for bbTPs sensitive to heat and moisture. This method reduces energy consumption by up to 90%. It enabled the production of recyclable TPU bead foams with 60% biobased content, and successful foaming of PLA and a newly developed biobased polyamide, Caramid, demonstrating strong flexibility and adaptability in processing biobased foams.
3. VITAL advanced the application of FIM (Foam Injection Moulding) to bbTPS by developing durable, fire resistant PLA grades now commercially available. Foaming was achieved using both chemical and physical blowing agents, supported by in situ monitoring. A machine learning based process control system improved part quality and reduced energy use. The project demonstrated real industrial parts—automotive interior components and refrigerator parts—using durable PLA, achieving 6–8% lightweighting in vehicles and successful substitution of fossil plastics such as HIPS, reducing greenhouse gas emissions. PLA recycling was shown to be feasible over multiple cycles with retained mechanical performance.
1. VITAL developed a novel 3D foam printing head capable of processing granulates with direct gas injection, eliminating the need for filament production and enabling density control during printing. The technology supports a wide range of plastics and achieved up to 66% weight reduction through foaming. Its functionality was demonstrated by producing a large-scale, recyclable PLA separation wall for cruise ships, showing improved mechanical and thermal performance over traditional PLA and offering a more sustainable alternative to glass-fibre composites.
2. Project created a steam free, radio frequency-based bead foaming process, ideal for bbTPs sensitive to heat and moisture. This method reduces energy consumption by up to 90%. It enabled the production of recyclable TPU bead foams with 60% biobased content, and successful foaming of PLA and a newly developed biobased polyamide, Caramid, demonstrating strong flexibility and adaptability in processing biobased foams.
3. VITAL advanced the application of FIM (Foam Injection Moulding) to bbTPS by developing durable, fire resistant PLA grades now commercially available. Foaming was achieved using both chemical and physical blowing agents, supported by in situ monitoring. A machine learning based process control system improved part quality and reduced energy use. The project demonstrated real industrial parts—automotive interior components and refrigerator parts—using durable PLA, achieving 6–8% lightweighting in vehicles and successful substitution of fossil plastics such as HIPS, reducing greenhouse gas emissions. PLA recycling was shown to be feasible over multiple cycles with retained mechanical performance.
Lightweight, recyclable bbTPs developed in VITAL reduce material use, emissions and reliance on fossil resources. Enhanced PLA recyclability, durable material performance and digital tools for process optimisation enable lower waste, faster and more reliable manufacturing and broader industrial uptake of sustainable plastics. By replacing fossil-based non recyclable foams, offering safer high performance alternatives, and enabling cost efficient production through advanced foaming technologies, VITAL strengthens Europe’s capacity for resource efficient and sustainable plastic processing supporting circular economy and climate neutrality goals.
The VITAL project delivered significant advancements across biobased thermoplastic materials and processing technologies, strengthening their potential to replace fossil plastics in demanding applications.
Project developed long lasting PLA based thermoplastic blends optimized for both Foam Injection Moulding and large scale 3D foam printing, progressing from labscale validation to commercial readiness (TRL 8–9). A comprehensive material database was created, including full rheological, thermal, mechanical and optical characterisation of virgin and foamed PLA grades, validated for Moldex3D simulations and published through external platforms to support industrial uptake.
Advanced digital modelling tools were developed to optimise screw design and processing parameters for mechanical recycling of PLA foams, enabling over 30% recyclate incorporation while minimising degradation. A full recycling cycle database was established, supporting circular economy goals and reducing dependence on virgin materials.
A novel 3D foam printing head capable of granulate processing and direct gas injection was developed and demonstrated (TRL 5/6). This system allows precise density control and efficient use of biobased materials. In parallel, the project produced a simulation tool combining CFD and AI surrogate modelling to predict foam extrusion behaviour and accelerate process optimisation.
Project developed Caramid, a new biobased polyamide suitable for bead foaming, with adjustable crystallinity and high temperature performance (TRL 3–4). A radio frequency based bead foaming process was also demonstrated, cutting energy use by up to 90% compared to steam moulding. Recyclable biobased TPU bead foams (100–150 kg/m³, 60% biobased content) and PLA bead foams were successfully produced, offering sustainable alternatives to conventional polyurethane and polystyrene foams.
New durable and fire resistant PLA grades suitable for FIM were developed. Innovations included in situ optical monitoring of foam cell growth and a machine learning based control system that improves part quality, reduces defects, and decreases energy use. Industrial trials produced automotive interior components and refrigerator parts from durable PLA, demonstrating weight reduction (6–8%), good performance and the potential to replace fossil materials like PP and HIPS.
The VITAL project delivered significant advancements across biobased thermoplastic materials and processing technologies, strengthening their potential to replace fossil plastics in demanding applications.
Project developed long lasting PLA based thermoplastic blends optimized for both Foam Injection Moulding and large scale 3D foam printing, progressing from labscale validation to commercial readiness (TRL 8–9). A comprehensive material database was created, including full rheological, thermal, mechanical and optical characterisation of virgin and foamed PLA grades, validated for Moldex3D simulations and published through external platforms to support industrial uptake.
Advanced digital modelling tools were developed to optimise screw design and processing parameters for mechanical recycling of PLA foams, enabling over 30% recyclate incorporation while minimising degradation. A full recycling cycle database was established, supporting circular economy goals and reducing dependence on virgin materials.
A novel 3D foam printing head capable of granulate processing and direct gas injection was developed and demonstrated (TRL 5/6). This system allows precise density control and efficient use of biobased materials. In parallel, the project produced a simulation tool combining CFD and AI surrogate modelling to predict foam extrusion behaviour and accelerate process optimisation.
Project developed Caramid, a new biobased polyamide suitable for bead foaming, with adjustable crystallinity and high temperature performance (TRL 3–4). A radio frequency based bead foaming process was also demonstrated, cutting energy use by up to 90% compared to steam moulding. Recyclable biobased TPU bead foams (100–150 kg/m³, 60% biobased content) and PLA bead foams were successfully produced, offering sustainable alternatives to conventional polyurethane and polystyrene foams.
New durable and fire resistant PLA grades suitable for FIM were developed. Innovations included in situ optical monitoring of foam cell growth and a machine learning based control system that improves part quality, reduces defects, and decreases energy use. Industrial trials produced automotive interior components and refrigerator parts from durable PLA, demonstrating weight reduction (6–8%), good performance and the potential to replace fossil materials like PP and HIPS.