Material Limitations and Processing Challenges of Bio‐Based Thermoplastics: A Review

ABSTRACT The increasing production and consumption of petro‐based plastics raise significant environmental concerns due to their persistence and accumulation in ecosystems. Biopolymers, derived from renewable sources such as plants and microorganisms, offer a sustainable alternative to traditional plastics. These materials are moldable and recyclable through thermal processes, providing versatility for various industrial applications, such as commercial thermoplastic materials. This review provides a comprehensive overview of biopolymeric thermoplastics (b‐bTPs), discussing their compositions, challenges, and recent advances. Key topics include the formulation of b‐bTPs using additives and blends to improve their properties, the application of advanced techniques such as microcellular injection molding, the recyclability of b‐bTPs foam parts, and future trends and prospects. This analysis highlights the potential of b‐bTPs to replace conventional plastics in numerous applications, contributing to a more sustainable industry.