J.-C. Albrecht, C. Mack
Fraunhofer ICT,
Germany
Keywords: Polylactide, bead foam, sustainability, biobased, drop-in substitute
Summary:
This presentation introduces EPLA, a plant-based bead foam developed as a sustainable alternative to conventional fossil-based foams, especially EPS. The motivation for EPLA arises from the need to reduce dependence on fossil resources and to foster more sustainable leightweight materials. Polylactic acid is identified as the most promising bioplastic for this purpose, due to its versatility, growing global production capacity, and ability to be tailored for specific applications through stereochemical modification. PLA is derived from renewable resources such as sugar, and ongoing research is exploring the use of waste streams and even CO₂ as feedstock, further enhancing its sustainability profile. EPLA’s development at Fraunhofer ICT is demonstrated through a series of projects. The BioFLIP project (2017) focused on creating lightweight, reusable pallets for logistics, showcasing EPLA’s recyclability and compatibility with existing EPS processing technologies. The BioPCM and InnPressMe projects (2019) advanced the integration of EPLA in biobased cooling boxes, combining thermal insulation, moisture regulation, and phase change materials for improved energy efficiency and functionality. In 2023, the PIMMS project demonstrated the potential of EPLA in sports goods, developing monomaterial PLA bicycle helmets and surfboards. These products are fully recyclable, meet European safety standards, and can be produced using industrial-scale processes. Currently, the Leihmmi project is developing lightweight, heatable sandwich materials for furniture and interior design, combining PLA and wood to create multifunctional, sustainable products with integrated heating and lighting features. These projects among others paved the paths for the improvement and prospective commercialisation of EPLA as a drop-in alternative for EPS molded parts. A key expertise of Fraunhofer ICT´s EPLA is the ability to tailor its mechanical properties by controlling crystallinity, enabling performance close to conventional expanded polystyrene (EPS). The presentation also outlines ongoing research aimed at further improving EPLA’s properties, including enhancement of mechanical and thermal performance, optimizing PLA compounds for home compostability, developing steamless molding techniques, and reducing material density. Efforts are also underway to validate EPLA in a broader range of industrial applications and to establish new partnerships for knowledge transfer and market adoption.