Researchers at the Georgia Institute of Technology have developed a bio-inspired way to turn unreliable recycled plastics into high-performance materials. The method takes cues from the layered structure of seashells. This breakthrough could make recycled plastics suitable for applications that require strength, consistency, and durability — from packaging to automotive parts and even building materials.

Tackling the Unpredictability of Recycled Plastics

Recycled plastics rarely replace virgin materials in demanding products. This is because their mechanical properties vary widely. Each batch contains polymers with different histories of stress, additives, and degradation. As a result, the material often becomes weaker and less predictable, which limits its use in products that require consistent strength or safety.

Aerospace engineering assistant professor Christos Athanasiou and his team looked to nacre, the iridescent layer found inside seashells, for inspiration also known as mother-of-pearl. In nature, nacre gains strength from its design: hard “bricks” of mineral bound together by softer “mortar” proteins. This combination allows the material to absorb energy and control cracks instead of breaking suddenly.

Building Reliability into Waste Materials

The researchers recreated this structure using chopped sheets of recycled high-density polyethylene (HDPE), a plastic used in industrial stretch wrap. They layered these stiff “bricks” with a softer adhesive polymer as the “mortar.” This approach reduced variability in mechanical performance by more than 68%. Importantly, the recycled composite performed as well as virgin HDPE while remaining consistent and reliable.

Because the method uses waste plastic in a high-value way, it could lower the cost of producing virgin packaging materials by up to 50%. In addition, it offers the potential to keep large amounts of plastic out of landfills.

Potential Across Design Disciplines

For packaging designers, this method opens the door to closed-loop systems where high-performance packaging comes from post-consumer waste. Product and automotive designers could also benefit, as the resulting materials meet demanding performance standards. Even architects and interior designers may find uses for these composites in sustainable surfaces or structural applications.

Looking ahead, the team plans to adapt the technique for other recycled plastics. They also aim to replace the adhesive layer with bio-based alternatives. This would make the material even more sustainable. Furthermore, the research has potential in space exploration, where reliable reuse of materials is essential.

Source & photo: Georgia Institute of Technology