Perspective: Ten Principles of Green Polymer Processing

ABSTRACT Polymer sustainability is commonly evaluated through feedstock selection, renewable materials, and chemical design; however, the role of polymer processing is often overlooked when determining environmental impact. Existing sustainability frameworks, including the principles of Green Chemistry and Green Engineering, provide important guidance for chemical and industrial development but do not fully address the unique challenges associated with polymer processing, such as high thermal and mechanical energy input, process complexity, scalability, and industrial implementation. In this work, 10 principles of green polymer processing are proposed to provide a sustainability‐focused framework specifically for polymer manufacturing and process development. These principles include solvent responsibility, intentional chemistry, energy efficiency, carbon consciousness, zero‐waste processing, process and material simplification, processing that is safe‐by‐design, data‐driven manufacturing, scalable design, and industrial integration. Each principle is discussed in the context of common polymer manufacturing operations including extrusion, thermoforming, additive manufacturing, solid‐state processing, and solvent‐based processing. The framework emphasizes that processing methods can significantly influence recyclability, energy consumption, additive usage, occupational safety, and overall environmental impact. Emerging technologies such as artificial intelligence, machine learning, real‐time sensing, and predictive modeling are also highlighted as tools for sustainable polymer manufacturing. These principles are intended to serve as an educational and conceptual guide for students, researchers, educators, and industry professionals developing more sustainable polymer processing technologies.