In recent year, there has been increasing concern about the growing amount of plastic waste coming from daily life. Different kinds of synthetic plastics are currently used for an extensive range of needs, but in order to reduce the impact of petroleum-based plastics and material waste, considerable attention has been focused on “green” plastics. In this paper, we present a broad review on the advances in the research and development of bio-based polymers analogous to petroleum-derived ones. The main interest for the development of bio-based materials is the strong public concern about waste, pollution and carbon footprint. The sustainability of those polymers, for general and specific applications, is driven by the great progress in the processing technologies that refine biomass feedstocks in order to obtain bio-based monomers that are used as building blocks. At the same time, thanks to the industrial progress, it is possible to obtain more versatile and specific chemical structures in order to synthetize polymers with ad-hoc tailored properties and functionalities, with engineering applications that include packaging but also durable and electronic goods. In particular, three types of polymers were described in this review: Bio-polyethylene (Bio-PE), bio-polypropylene (Bio-PP) and Bio-poly(ethylene terephthalate) (Bio-PET). The recent advances in their development in terms of processing technologies, product development and applications, as well as their advantages and disadvantages, are reported.

Nowadays, all production, from the smallest ones to large companies, and research activities are affected by the use of 3D printing technology. The major limitation, in order to cover as many fields of application as possible, is represented by the set of 3D printable materials and their limited spectrum of physico-chemical properties. To expand this spectrum and employ the 3D-printed objects in areas such as biomedical, mechanical, electronical and so on, the introduction of fibers or particles in a polymer matrix has been widely studied and applied. In this review, all those studies that proposed modified polymer presenting advantages associated with rapid prototyping are reported.

Three commercial filaments for Fused Deposition Modeling (FDM) were selected to study the influence of polymer formulation on the printing quality and mechanical properties of FDM specimens. The three filaments were all based on polylactic acid (PLA) as the matrix, and they are sold as PLA filaments. The printing quality was tested by printing one complex shape with overhang features. The marked shear thinning behavior for two filaments was observed by rheology. The filaments were also studied by scanning electron microscopy and thermogravimetric analysis (TGA) to unveil their composition. The filaments with the best printing quality showed the presence of mineral fillers, which explained the melt behavior observed by rheology. The tensile testing confirmed that the filled PLA was the best-performing filament both in terms of printing quality and thermomechanical performance, with a p-value = 0.106 for the tensile modulus, and a p-value = 0.615 for the ultimate tensile strength.

An innovative recycling process for thermoset polymer composites developed by Connora Technologies (Hayward, CA, USA) was studied. The process efficacy has already been tested, and it is currently working at the plant level. The main aspect investigated in the present paper was the environmental impact by means of the Life Cycle Assessment (LCA) method. Because of the need to recycle and recover materials at their end of life, the Connora process creates a great innovation in the market of epoxy composites, as they are notoriously not recyclable. Connora Technologies developed a relatively gentle chemical recycling process that induces the conversion of thermosets into thermoplastics. The LCA demonstrated that low environmental burdens are associated with the process itself and, furthermore, impacts are avoided due to the recovery of the epoxy-composite constituents (fibres and matrix). A carbon fibre (CF) epoxy-composite panel was produced through Vacuum Resin Transfer Moulding (VRTM) and afterwards treated using the Connora recycling process. The LCA results of both the production and the recycling phases are reported.

The use of polyhedral oligomeric silsesquioxanes (POSSs) for making polymer composites has grown exponentially since the last few years of the 20th century. In comparison with the other most commonly used fillers, POSSs possess the advantage of being molecules. Thus, this allows us to combine their nano-sized cage structures, which have dimensions that are similar to those of most polymer segments and produce a particular and exclusive chemical composition. These characteristics linked with their hybrid (inorganic–organic) nature allow researchers to modify POSS according to particular needs or original ideas, before incorporating them into polymers. In this present study, we first start with a brief introduction about the reasons for the rediscovery of these nanoparticles over the last 25 years. Starting from the form of POSS that is most widely used in literature (octaisobutyl POSS), this present study aims to evaluate how the reduction of symmetry through the introduction of organic groups favors their dispersion in polystyrene matrix without compromising their solubility.

Polyetherimide (PEI) blends modified by either polycarbonate (PC) or polyethylene terephthalate glycol-modified (PETG) were prepared. The latter modifier (PETG) was an industrial grade widely used for fused deposition modelling (FDM) printing. PEI blends were compared to Ultem 9085, which is the standard PEI grade for FDM printing in advanced applications. All the blends were thoroughly characterized in terms of their rheological, morphological, thermomechanical and tensile properties. Ultem 9085 showed improved rheology for processing over standard PEI. PEI/PC blends with 10 wt % of modifier developed here closely matched the viscosity behavior of Ultem 9085. On the other hand, the blends with low PC content (i.e., less than 20 wt %) outperformed Ultem 9085 in terms of thermal and tensile properties. When PETG was added, similar tensile properties to Ultem 9085 were found. The immiscibility for PC contents higher than 20 wt % deteriorated the tensile properties, making it less attractive for applications, although melt viscosity decreased further for increasing PC contents.