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.
