Versatile FUran-based polymeRs for strIct and high value applicatiOns in packaging, aUtomotive and underwater environmentS

Project Information

FURIOUS

Grant agreement ID: 101112541

DOI

10.3030/101112541

EC signature date 22 May 2023

Start date 1 June 2023

End date 31 May 2027

Funded under

• Food, Bioeconomy Natural Resources, Agriculture and Environment

Total cost

€ 4 498 017,50

EU contribution

€ 4 498 017,50

Coordinated by

UNIVERSITA DEGLI STUDI DI PERUGIA
Italy

Periodic Reporting for period 2 - FURIOUS (Versatile FUran-based polymeRs for strIct and high value applicatiOns in packaging, aUtomotive and underwater environmentS)

Reporting period: 2024-12-01 to 2026-03-31

Summary of the context and overall objectives of the project

The FURIOUS project addresses the critical regulatory and environmental requirement to replace fossil-based plastics with sustainable, high-performance alternatives in high-demand industries. The research aims to synthesize flexible furan-based biopolymers (PxF) from 99.9% pure 2,5-furandicarboxylic acid (2,5-FDCA). The goal is to provide financially viable, bio-based materials that are specifically designed to withstand harsh functional settings in which typical bioplastics fail. The project specifically optimizes high-purity monomer production to engineer flexible, gamma-sterilizable flexible packaging for biomedical application and rigid packaging, with high barrier to humidity and oxygen, for electronic applications. In parallel, the project developed antibacterial electrospun filters and interior display panels for the automotive industry; 3D-printable elastomeric grippers, UV-crosslinkable sensors and elastomeric optical fibers for harsh underwater environments. On the circularity front, we demonstrated that these formulations can reliably sustain 100% enzymatic depolymerization, mechanical and chemical (by DES and ILs) recyclability.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Technical and scientific activities of the period aimed to reach raw monomer purity optimization, advanced product processing, circular degradation testing, and sustainability modeling. The first phase focused on scaling up and improving the purity of the project's core bio-based building block. The consortium successfully synthesized and produced 2,5-furandicarboxylic acid (2,5-FDCA) at a purity of 99.9 wt%. To eliminate chemical contaminants that naturally impede long-chain polymer formation, researchers expanded a chemical esterification technique to turn raw FDCA into very pure furandicarboxylic acid dimethyl ester (DMF). Building on these high-purity inputs, structural work switched to customized polymer design for the three main industrial sectors. For flexible packaging in biomedical and electronics applications, eco-design concepts led the synthesis of four specific random copolymers and two homopolymers. Twin-screw extrusion was used to manufacture robust, UV-resistant PC/PEF and compatible PEF/PEN blends into clear interior camper display panels, while electrospinning processes were used to successfully transform antibacterial copolymers into functional cabin air filters. Synthesis in underwater contexts focused on unique resin frameworks for stereolithography-based 3D printing of aquatic sensors, elastomeric optical fiber, and fused deposition modeling of durable soft robotic grippers. A precise analytical procedure for targeted enzymatic hydrolysis was developed, resulting in 100% total depolymerization of furanic polymers back to their original starting components. Gamma irradiation treatments were observed to improve enzymatic breakdown kinetics in a dose-dependent manner, whereas recurrent mechanical extrusion loops proved PxF's structural durability during numerous physical recycling cycles. Simultaneously, these empirical physical parameters were used to construct an open-access database, that allowed, by machine learning algorithms to anticipate final physical features based on polymer processing factors. Cradle-to-gate LCA and LCC were optimized to maximize industrial scale-up emissions and recycling yields.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The potential benefits of technological advancements are significant, providing a plausible path to decoupling high-value engineering materials from petrochemical feedstocks. The project intends to speed up the transition to a climate-neutral, zero-pollution circular economy by producing functional drop-in bioplastics that meet stringent performance standards, such as gamma-sterilization tolerance for medical packaging and marine environment resilience. To achieve future adoption and convert the project outcomes beyond its current TRL to full-scale commercialization, many critical needs must be addressed: i) To align end-of-life findings with changing frameworks (such as the EU Packaging and Packaging Waste Regulation), the marine biodegradation and multi-cycle mechanical recycling qualities must be certified according to international standards. ii) to establish explicit intellectual property mechanisms among consortium partners.