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Artificial Intelligence-Designed Thermoplastic Materials for Sustainable Packaging and Electronics

Project description

Circular solution for sustainable thermoplastic materials

Green transition efforts have been accelerating in recent years, achieving significant gains and breakthroughs through the introduction of key solutions, technologies, and policies. Unfortunately, entire sectors and industries remain unaffected, continue to produce significant amounts of waste, or require critical raw materials. The EU-funded AIM-PACE project will develop a key solution for transforming many underutilised industrial side streams and biogenic CO2 into high-performance bio-based thermoplastics. It will combine multidisciplinary experience in fields including advanced computer simulation and microbial engineering with an agentic AI platform to introduce key circularity solutions, improve and optimise current PHAs, enhance key properties, and encourage their use in a variety of applications.

Objective

AIM-PACE will transform underutilized industrial side-streams and biogenic CO2 into high-performance, bio-based thermoplastics. The project combines microbial engineering, advanced computer simulations, and an agentic AI platform with multi-objective optimization to evolve current PHAs into materials with unprecedented combination of properties. These next-generation PHAs will make possible monomaterial packaging that replaces multilayer fossil-based structures, as well as wearable electronics that avoid the need for high filler-loaded plastics, cutting electronic waste at its source. Four demonstrators will validate both performance and manufacturability up to TRL 7: disposable electrodes, sensor housings, pill organizers, and industrial films/trays. Circularity is embedded from the start: material reduction, reuse, and mechanical recycling will be prioritized, while compostability will be confirmed for applications where recycling is not feasible. To further improve efficiency, Bayesian-guided process optimization will reduce energy and material inputs across the entire value chains. In total, AIM-PACE will establish seven new technologies and four fully integrated EU-based value chains, spanning from feedstock valorization to end-use applications. The project will surpass fossil-based benchmarks by achieving cradle-to-grave greenhouse gas emissions that are 30–50% lower, primary energy demand that is 15% lower, and 15% lower water consumption per kilogram of material produced. At least 80% of feedstocks will be sourced from agri-food residues and industrial side-streams, while at least 80% of material performance will be retained after three recycling loops. All processes will comply with DNSH criteria. From the outset, stakeholders, including end users, recyclers, waste managers, and policymakers, will be actively engaged to ensure regulatory readiness, infrastructure alignment, and accelerated market uptake.

Fields of science (EuroSciVoc)

Keywords

Programme(s)

Topic(s)

Funding Scheme

HORIZON-JU-IA - HORIZON JU Innovation Actions

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Call for proposal

(opens in new window) HORIZON-JU-CBE-2025

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Coordinator

TEKNOLOGIAN TUTKIMUSKESKUS VTT OY
Net EU contribution
€ 1 420 949,75
Address
TEKNIIKANTIE 21
02150 Espoo
Finland
Region
Manner-Suomi Helsinki-Uusimaa Helsinki-Uusimaa
Activity type
Research Organisations
Links
Total cost
€ 1 420 949,75

Participants (13)