By the late 1970s, plastics had emerged as the most widely used materials globally. The discovery, development, and processing of diverse polymeric materials have profoundly shaped modern life and driven the expansion of numerous industries. Given the widespread interest in the utilization of these materials, it has become increasingly imperative to design their life cycles from the outset. This approach aims to maximize their utility while minimizing their environmental footprint. This review aims to identify and analyze the key challenges in polymer processing applicable to both additive and formative manufacturing methods, emphasizing the relationship between processing and recycling within the framework of sustainability. Modern polymer processing techniques play a crucial role in enhancing the sustainability of polymer products by improving recycling potential (with consideration of polymer type, source, and additives), cost-effectiveness, carbon footprint, and key properties such as durability, lifespan, performance, and environmental impact. It will also explore the concept of the circular economy and its integration into modern processing methods, including extrusion, injection molding, and 3D printing. Additionally, current polymer recycling methods are analyzed with respect to their effectiveness, sustainability, and compatibility with the original materials. Moreover, the discussion emphasizes the benefits of a circular economy compared to a linear one by exploring the concepts of closed-loop and open-loop systems, along with their diverse applications depending on the material and the initial processing method employed. To ensure that humanity continues to benefit from polymer materials while striving for a waste-free environment, it is essential to integrate the principles of sustainable development from the very beginning.

This work proposes a new method for obtaining poly(3-hydroxybutyrate) (PHB)/microfibrillated cellulose (MC) composites with more balanced properties intended for the substitution of petroleum-based polymers in packaging and engineering applications. To achieve this, the MC surface was adjusted by a new chemical route to enhance its compatibility with the PHB matrix: (i) creating active sites on the surface of MC with γ-methacryloxypropyltrimethoxysilane (SIMA) or vinyltriethoxysilane (SIV), followed by (ii) the graft polymerization of methacrylic acid (MA). The high efficiency of the SIMA-MA treatment and the lower efficiency in the case of SIV-MA were proven by the changes observed in the Fourier transform infrared FTIR spectra of celluloses. All modified celluloses and the PHB composites containing them showed good thermal stability close to the processing temperature of PHB. SIMA-modified celluloses acted as nucleating agents in PHB, increasing its crystallinity and favoring the formation of smaller spherulites. A uniform dispersion of SIMA-modified celluloses in PHB as a result of the good compatibility between the two phases was observed by scanning electron microscopy and many agglomerations of fibers in the composite with unmodified MC. The dual role of SIMA-MA treatment, as both compatibilizer and plasticizer, was pointed out by mechanical and rheological measurements. This new method to modify MC and obtain PHB/MC composites with more balanced stiffness–toughness properties could be a solution to the high brittleness and poor processability of PHB-based materials.

Nanocomposite hydrogels are gaining significant attention for biomedical applications in soft tissue engineering due to the increasing demand for highly flexible and durable soft polymer materials. This research paper focused on investigating and optimizing a procedure for the development of novel nanocomposite hydrogels based on poly(2-hydroxyethyl methacrylate)-co-(2-acrylamido-2-methylpropane sulfonic acid) (HEMA/AMPSA) copolymers. These hydrogels were synthesized through a grafting-through process, where the polymer network was formed using a modified clay crosslinker. The layered double hydroxide (LDH) clay modified with 3-(trimethoxysilyl)propyl methacrylate (ATPM) was synthesized using a novel recipe through a two-step procedure. The nanocomposite hydrogel compositions were optimized to achieve soft hydrogels with high flexibility. The developed materials were analyzed for their mechanical and morphological properties using tensile and compressive tests, transmission electron microscopy (TEM), scanning electron microscopy (SEM), and micro-computed tomography (micro-CT). The swelling behavior, network density, and kinetic diffusion mechanism demonstrated the specific characteristics of the materials. The modified LDH-ATPM was further characterized using Thermogravimetry (TGA), FTIR-ATR and X-ray diffraction (XRD). Biological assessments on human adipose-derived stem cells (hASCs) were essential to evaluate the biocompatibility of the nanocomposite hydrogels and their potential for soft tissue applications.