Bridging the Gap Between Laboratory Research and Industrial Implementation of Green Composite Technologies: A Review

ABSTRACT The imperative for sustainable materials has escalated amid global environmental concerns, resource depletion, and stringent regulations on greenhouse gas emissions. Green composite technologies leveraging renewable plant fibers and bio‐based polymer matrices offer a pathway to high‐performance materials with reduced ecological impact. This review critically examines the full lifecycle of green composites, from laboratory breakthroughs to industrial implementation, identifying key barriers and enablers. Laboratory achievements in fiber surface modification, hybrid composite design, and additive manufacturing have demonstrated superior tensile strengths and Young's moduli, rivaling conventional composites. Yet, fewer of these systems advance beyond mid‐level technology readiness levels due to scale‐up challenges such as fiber variability, moisture sensitivity, and process reproducibility. Economic analyses reveal that raw material and processing cost premiums are higher than those of synthetic alternatives at low volumes, underscoring the need for supply‐chain consortia and shared pilot facilities to achieve cost parity at annual production volumes above 1000 t. Organizational hurdles, risk aversion, regulatory gaps, and knowledge transfer deficits further impede commercialization. Successful case studies in automotive interior panels, structural wall elements, and biodegradable packaging trays demonstrate that targeted industry‐academia partnerships, standardized testing protocols, and modular pilot lines can accelerate technology readiness level advancement. This review proposes a phased roadmap standardization and pilot demonstrations in the short term; digital manufacturing integration and workforce development in the medium term; and dedicated greenfield facilities and circular economy infrastructure in the long term to bridge the “valley of death” and facilitate broad adoption of sustainable composites.