SBIR Phase II: Dynamic Covalent Polymers for Transition to Closed-loop Plastics Economy

Award ID: 2538148

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase II project is in commercializing a new, "infinitely" re-polymerizable material called Engineered Circular Adaptive Networks (ECANs). This technology allows chemically recalcitrant plasticsspecifically thermosets used in cars and electronicsto be fully reused. Unlike common plastics, thermosets are usually impossible to melt down once formed, often simply discarded. By using ECANs, these tough materials can be reused indefinitely in a "closed loop," reducing the need for expensive, brand-new plastic. Integrating this technology into manufacturing strengthens the supply chain by providing a reliable source of high-quality materials. This innovation allows companies to reuse their own materials, lowering production costs and energy consumption. The ECAN polymer platform is a versatile technology capable of producing high-value resins for films, fibers, adhesives, composites, and elastomers. Unlike conventional polymers, ECANs are Covalent Adaptable Networks (CANs) that utilize dynamic, associative covalent bond exchange reactions to enable chemical recycling within mixed waste streams. This unique chemistry allows for low-temperature recovery and remanufacturing into virgin-quality resins at a significantly reduced cost compared to traditional processing methods. Building on Phase Is successful proof-of-conceptwhich validated material property retention across multiple lifecyclesthis Phase II project will focus on de-risking and scaling the platform at both the manufacturing and re-polymerization stages. Key objectives include optimizing ECAN material performance to meet specific customer requirements and establishing industry-compatible production through U.S.-based contract manufacturing partnerships for synthesis and polymerization. Additionally, the project will develop a pilot-scale depolymerization system to demonstrate low-loss processing and explore application-specific formulations to serve broader consumer, electronic, and other markets. By validating performance, scalability, and reusability across these targeted industries, the project will advance the ECAN platform toward full commercialization. These efforts will establish the necessary infrastructure and formulation capabilities to ramp up to commercial scale, and lay the groundwork for a robust, closed-loop plastics economy. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

NSF Program Director: Rajesh Mehta