Recyclable Polymers and Circular Material Design for Sustainable Manufacturing

The unprecedented rise in global plastic production has precipitated a severe environmental crisis, with only a fraction of plastic waste being effectively recycled. This review comprehensively examines the role of recyclable polymers and circular material design as pivotal solutions for sustainable manufacturing. We discuss recent advances in recyclable polymer chemistries including thermoplastics, dynamic covalent networks, and biodegradable polymers and analyze circular design strategies that operate from the molecular to the product level. The integration of digital technologies such as blockchain for material traceability and artificial intelligence for sorting and polymer discovery is evaluated for their potential to enhance circularity. Additionally, we address the significant technical, economic, and policy challenges hindering widespread adoption and highlight emerging trends in bio-based feedstocks and AI driven innovations. By emphasizing multidisciplinary collaboration and systemic change, this review outlines a roadmap for transitioning toward a regenerative polymer economy aligned with the United Nations Sustainable Development Goals. The findings provide critical insights for researchers, policymakers, and industry stakeholders striving to design plastics that are both functional and environmentally responsible.