Harnessing shellac for sustainable materials: progress from traditional resin to multifunctional composites

Abstract This review systematically scrutinizes recent progress in the design, modification, and potential applications of shellac-based composites, providing a link between its molecular structure, inherent characteristics, and modern performance requirements. The discourse begins with an analysis of shellac’s molecular architecture, intrinsic properties, and traditional uses of shellac for providing a foundational understanding. Traditional applications in pharmaceuticals, food coatings, and decorative finishes are reviewed alongside modern modification techniques that enable advanced uses in electronics, sensors, stealth technologies, and other high-performance sectors by improving shellac’s mechanical, thermal, electrical, and barrier properties. The environmental and economic advantages of shellac, positioned as a sustainable alternative to synthetic polymers, are assessed, with a techno-economic perspective highlighting its commercial viability and market potential. Current challenges including variability in natural sources, scalability of composite production, and regulatory considerations are critically discussed, with proposed strategies to address them. This work underscores shellac’s potential to transition from a traditional resin to a versatile, competitive, and eco-efficient material for high-impact industrial applications.