How a seashell-like architecture tames variability in recycled plastics

What is it about?

Recycled plastics are essential for cutting waste, but they’re notoriously unpredictable: one batch can be strong, the next brittle. That variability scares off manufacturers who need consistent performance. Our study borrows a trick from seashells (nacre). We build a “brick-and-mortar” structure where rigid layers of recycled plastic (“bricks”) are bonded by thin, soft adhesive layers (“mortar”). This architecture spreads stresses and prevents weak spots from turning into cracks, so the material behaves more consistently—even when the feedstock varies. We combine experiments with a mechanics-based, uncertainty-aware model to show why this works and how to design it. In a packaging case study (stretch-wrap films), the approach can maintain strength and reliability while potentially cutting material costs by up to ~50%—and keeping more plastic out of landfills.

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Photo by Nick Fewings on Unsplash

Photo by Nick Fewings on Unsplash

Why is it important?

Manufacturers avoid recycled plastics because performance varies. Our bioinspired design offers a practical, scalable route to predictable recycled materials without expensive purification. The work provides clear design rules backed by testing and modeling, enabling high-volume products—like films and packaging—to switch to recycled content with less risk, lower cost, and reduced environmental impact.

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