Plastic Bio-Based Polyamide As A Plastic Alternative

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How can new bio-based and biohybrid materials with improved functionality be developed more quickly? This question is being addressed jointly by six Fraunhofer Institutes in the flagship project SUBI²MA. A bio-based polyamide developed by Fraunhofer researchers serves as a model.

The plastics industry is undergoing a transformation: petroleum-based materials are increasingly being replaced by sustainable alternatives. However, sustainability alone is not enough—bio-based plastics need to deliver more. In the flagship project SUBI²MA, Fraunhofer Institutes are working on accelerating the development of new materials that are not only environmentally friendly but also functionally superior. They are focusing on three main objectives: advancing new bio-based materials, creating new biohybrid materials, and implementing digital fast-track development.

In the SUBI2MA project, the combined expertise of six institutes has now enabled us to think in new ways, scale the caranlactams, optimize the caramides, and develop them even more specifically for certain applications.

Dr. Paul Stockmann

At the center of the bio-based materials development is Caramid, a bio-based high-performance polyamide. It is derived from 3-Caren, a terpene that occurs as a by-product in large quantities during cellulose production. Terpenes are natural organic compounds found in many plant parts such as leaves, flowers, and roots, and are the main components of resins and essential oils.

Researchers at the Straubing branch of the Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB developed the monomers 3S- and 3R-Caranlactam, as well as the Caramides derived from them, from 3-Caren about ten years ago. "In the SUBI²MA project, the combined expertise of six institutes has now enabled us to think in new ways, scale the Caranlactams, optimize the Caramides, and develop them even more specifically for certain applications," says Dr. Paul Stockmann from Fraunhofer IGB.

Bio-Based Building Blocks Integrated into High-Performance Polymers

Caramides have exceptional thermal properties due to their chemical structure, making them attractive for numerous applications: from gears in mechanical engineering to safety glass, lightweight panels, foams, protective textiles, and even surgical sutures. Monofilaments, foams, and plastic glasses have already been manufactured from the new polyamide, which, in addition to its high-temperature stability, demonstrates great versatility. "During the project, it became apparent that the two Caranlactam monomers lead to different Caramides that vary significantly in their properties," the researcher explains. "For example, Caramide-S, due to its partial crystallinity, is suitable for fibers, while Caramide-R, because of its so-called amorphous or irregular structure, is ideal for foams."

By integrating bio-based building blocks into high-performance polymers, a functional advantage is achieved. Caramids are therefore not only bio-based but also exhibit better performance than fossil-based materials.

Dr. Paul Stockmann

Another property is the so-called chirality, a spatial characteristic of molecules where two structural variants exist that are mirror images but not superimposable. This can influence the physical, chemical, or biological functions of a material. As a result, Caramide's material properties can be more finely tuned, for example, for specialized applications in medical technology or sensor systems. "By integrating bio-based components into high-performance polymers, a functional advantage is achieved. Caramides are therefore not only bio-based but also show better performance than fossil-based materials," concludes Stockmann.

Biomolecules Give Well-Known Materials New Properties

The second objective involves the development of new biohybrid materials. The integration of functional biomolecules imparts new functions to well-established materials. The areas of application are diverse, ranging from bio-based flame retardants for materials to additives or enzymes that accelerate the decomposition of petroleum-based PET. Fiber-reinforced composites incorporating biomaterials and diagnostic tools such as innovative biosensors are additional fields of application.

"An important function enabled by the integration of specific proteins is the hydrophobization of materials, meaning the targeted modification of a material's surface to make it water-repellent," explains Ruben Rosencrantz, a scientist at the Fraunhofer Institute for Applied Polymer Research IAP. Such water-repellent materials are used, for example, in protective workwear and outdoor textiles or medical applications and could potentially replace environmentally harmful substances like PFAS in the long term.

Digitalization As A Turbo for Material Development

Based on their own experience, the researchers know: material development and substitution still take a long time, and it is often entirely uncertain which specific applications a material will be best suited for. The scientists aim to change this with their third goal, Fast-Track Development. To do this, they are digitizing material development: "We are creating a comprehensive, structured, and digitized data foundation in the lab using simulations," says Frank Huberth from the Fraunhofer Institute for Mechanics of Materials IWM. "In this digital value chain, property profiles and sustainability can be estimated earlier in the future through the combination with data-driven methods and simulations, significantly accelerating development times for materials and products."

Konrad Steiner from the Fraunhofer Institute for Industrial Mathematics ITWM adds: "With the help of digital demonstrators, for example for protective textiles and tires, we can save development steps and evaluate the effects and performance of the new Caramid fibers early on without laboriously producing and testing a textile or a complete tire."

Outlook: From Laboratory to Application

An important driving force in the concept development was the strong interdisciplinary collaboration between the six institutes—Fraunhofer IGB, IAP, IWM, ITWM, LBF, and ICT—and an external subcontractor within the project. For instance, a major hurdle, the scaling of synthesis processes, was tackled collaboratively. The two monomers can now be produced on a kilogram scale. An increase in funding for the flagship project now makes it possible to test additional, industrially viable demonstrators, partially in direct cooperation with industry. The monomers are soon to be made available to an associated industry partner, who will process the raw material on their systems for a specific application.

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