#Research & Development

2025-12-11

Fraunhofer CCPE presents the “Monomaterial Design Set” – Innovative solutions for circular product design

Monomaterial structures made of biopolymers (also possible in PET or polyamide) © Fraunhofer CCPE/Mike Henning

Composite materials made from different types of plastic often extend the lifetime of products but make recycling more difficult in the circular economy. That is why Fraunhofer CCPE has developed the “Monomaterial Design Set”. This new approach helps to reduce the variety of plastics used in durable products and offers circular solutions for designers and product developers.

The plastics processing industry faces a major challenge: How can companies develop durable products that are also circular? The Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE has found a solution: the “Monomaterial Design Set”. This novel approach makes it possible to avoid combinations of different plastics in numerous applications, thereby increasing recyclability without compromising the performance of the end product.

Innovative approaches for designers and product developers

The “Monomaterial Design Set” is aimed at designers and product developers who want to make durable and high-specification products more recyclable. Thanks to research conducted by Fraunhofer CCPE, the same thermoplastic can be integrated into a product in different forms (e.g., as fibers, foam or casting compound). PET, PLA, and PA thermoplastics have already been tested. The structure of the design set allows different manufacturing technologies to be combined to create complex components with a wide variety of shapes and high performance. The processes used include injection molding, foam production, and the processing of textiles and self-reinforced panels.

A key objective of the Monomaterial Design Set is to achieve 100% recyclability of the products, as only one type of plastic is used, and so called “monomaterial.” By eliminating the use of adhesives, disassembly of components becomes unnecessary. In addition, Fraunhofer CCPE offers solutions for recyclable color pigments and flame retardant additives that ideally complement this approach. Depending on the selected material base and regional recycling infrastructure, companies are offered individual advice on how to make optimal use of existing collection systems or recycling facilities.

The heads of the Research Department Application and Demonstration, Dipl.-Des. Sabrina Schreiner and Dr. Jonathan Haas, see enormous innovation potential in the Monomaterial Design Set. This approach makes it possible to implement sustainability and circular economy goals as early as product development stage. Exciting demonstrators such as the “circular child seat” and an insulated “reusable transport box” made from monomaterials have already been developed in the cluster. The transferability of this concept to various industries and product segments is very promising.

The “Circular Child Seat” demonstrator in monomaterial design © Fraunhofer CCPE

Design competition: Monomaterial furniture for tomorrow

In addition, Fraunhofer CCPE has taken on the scientific support of Nowy Styl DACH's “Re:think Design Competition”. The “Monomaterial Design Set” plays a decisive role here: designers can use it as a source of inspiration and technical framework to develop innovative designs for 100% recyclable soft seating furniture. The winners of the competition will be announced on April 23, 2026. Registration is open until December 3.

Geotextiles made from recycled materials: GREEN leads the way into the industry

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RE&UP’s Next-Gen Cotton fibers power Zalando private label t-shirt collection crafted from innovative recycled textiles

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