Artificial Intelligence-Designed Thermoplastic Materials for Sustainable Packaging and Electronics

AIM-PACE will transform underutilized industrial side-streams and biogenic CO2 into high-performance, bio-based thermoplastics. The project combines microbial engineering, advanced computer simulations, and an agentic AI platform with multi-objective optimization to evolve current PHAs into materials with unprecedented combination of properties. These next-generation PHAs will make possible monomaterial packaging that replaces multilayer fossil-based structures, as well as wearable electronics that avoid the need for high filler-loaded plastics, cutting electronic waste at its source. Four demonstrators will validate both performance and manufacturability up to TRL 7: disposable electrodes, sensor housings, pill organizers, and industrial films/trays. Circularity is embedded from the start: material reduction, reuse, and mechanical recycling will be prioritized, while compostability will be confirmed for applications where recycling is not feasible. To further improve efficiency, Bayesian-guided process optimization will reduce energy and material inputs across the entire value chains. In total, AIM-PACE will establish seven new technologies and four fully integrated EU-based value chains, spanning from feedstock valorization to end-use applications. The project will surpass fossil-based benchmarks by achieving cradle-to-grave greenhouse gas emissions that are 30–50% lower, primary energy demand that is 15% lower, and 15% lower water consumption per kilogram of material produced. At least 80% of feedstocks will be sourced from agri-food residues and industrial side-streams, while at least 80% of material performance will be retained after three recycling loops. All processes will comply with DNSH criteria. From the outset, stakeholders, including end users, recyclers, waste managers, and policymakers, will be actively engaged to ensure regulatory readiness, infrastructure alignment, and accelerated market uptake.