Sustainable foam production from waste plastics with comprehensive materials characterization

Overview

This program converts recycled disposable plastic waste, such as PET and PLA bottles, into high-value foam core materials. The goal is to deliver foams with comparable or superior mechanical, thermal, and chemical performance relative to commercial products, while reducing production costs, lowering carbon footprints, and diverting plastic waste from landfills and the environment. The approach supports a more efficient waste management system and provides manufacturers with sustainable alternatives for foam-based products.

The initiative is led by Dr. Wen Zhang's lab at NJIT, which brings extensive experience in polymer synthesis and characterization. The lab has a track record of industry-funded research with companies such as 3M, Millipore, and Pall, and offers a comprehensive suite of analytical capabilities to validate recycled-foam performance against industry benchmarks.

Technical specifications

Foam development and processing:

• Conversion of recycled PET and PLA waste streams into foam core materials
• Innovative processing techniques tailored to waste-plastic feedstocks
• Optimization of foam morphology, pore structure, and mechanical performance

Holistic characterization capabilities:

• Morphology and surface analysis: SEM, AFM, and BET for pore size, size distribution, roughness, local hydrophobicity, and surface topography
• Mechanical properties: hardness, elasticity, and tensile strength testing
• Surface and interfacial properties: zeta potential, contact angle, and adhesiveness toward specific substances
• Chemical and structural analysis: FTIR/Raman for functional groups and surface distribution, XRD for crystallinity, and XPS for chemical composition
• Thermal and emissions analysis: TGA for thermal stability, plus EEM and fluorescence microscopy for vapor release and VOC emissions
• Safety and durability testing: antibacterial assays, water absorbency tests, ICP-MS for heavy metal release, and chemical aging under acid/base conditions

Technology readiness level

The project is structured across four phases over approximately 14 months. Phase 1 (3 months) covers sample acquisition, including procurement of commercial foam or sponge benchmarks and collection and processing of waste plastics. Phase 2 (6 months) focuses on comprehensive characterization and analysis of foam properties. Phase 3 (3 months) is dedicated to validation and optimization of foam materials. The final phase (2 months) addresses data analysis, reporting, and publication.

The underlying characterization methods have been validated through prior work on polymer membranes, thin films, and microplastics, supported by funding from industry partners. Foam-specific validation, including benchmarking against commercial products and assessment of durability during use, represents the next stage of development. The team is positioned to deliver actionable insights for future product design and production decisions.