Bioplastic Fibres: Processing, Properties, Applications and Challenges

Abstract

Polymer fibres are foundational to modern material systems, offering adjustable mechanical properties, chemical functionality and formability across sectors such as textiles, packaging, biomedical and composites. Bioplastic fibres, derived from renewable or biodegradable polymers, present a promising route toward reducing dependence on petrochemical resources while supporting circular material flows. However, translating bioplastic fibres into competitive alternatives requires overcoming their intrinsic limitations in processability, cost and end-of-life management, to fully reap their benefits. This review evaluates the materials, processing techniques and structure–property relationships underpinning bioplastic fibre performance. Emphasis is placed on molecular orientation, crystallinity and surface functionality as determinants of mechanical, thermal and biodegradation behaviour of bioplastic fibres. Fibre-specific challenges such as brittleness, moisture sensitivity, narrow thermal processing windows and blend incompatibility are discussed in the context of polymer physics, chemical modification and advanced manufacturing. Opportunities arising from copolymerisation, nanocomposite integration, functionalisation and closed-loop recycling are explored with cross-sectoral examples. This review provides a scientifically rigorous, application-focused framework to guide the sustainable development and industrial adoption of bioplastic fibre technologies.

Graphical Abstract

Keywords

Bioplastics / Biopolymers / Polymer fibres / Polymer processing / Sustainable materials / Biodegradation

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Funding

Australian Research Council(DP220100845)

RIGHTS & PERMISSIONS

Donghua University, Shanghai, China

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